The art and science of injection moulding PVC
Cheltenham-based Injection Mouldings (IML) Ltd is set for a further period of expansion following the recent doubling of its factory size. Key to growth this year will be the long-standing partnership with materials supplier, Dugdale Ltd.
Injection Mouldings Ltd manufactures over a million components per month using PVC compounds supplied by the Sowerby Bridge based company. The collaboration stretches back to the beginnings of the company and has gone from strength to strength ever since.
Injection Mouldings (IML) Limited was established in 1994 to provide high quality moulded products in a number of different industrial sectors. IML Managing Director Steve Rawse says that ‘we have the ability to turn even the most obscure moulding requests into reality. Our expertise in PVC injection moulding is key to our success and accounts for some 40% of our current output. Important markets include the construction, medical & specialized engineering sectors. And part of the excellent fit we have with Dugdale is that the company can supply us with both rigid and flexible grades.’
Andy Tombs, Dugdale Business Development Manager says that ‘we are delighted to be keeping pace with all the developments here at IML. IML is a true innovator in PVC and at Dugdale we are continually developing our materials for the benefit of the injection moulding industry.’
Andy adds that ‘from the outside, successful PVC moulding may appear to be something of a ‘black art’. The material demands respect. We know that, as a leading practitioner, Injection Mouldings Ltd is extremely meticulous in all that it does; including the understanding of the manufacturing process, the company’s investment in people, the approach to process control, the care and upkeep of the process equipment, the design of the tooling and many other matters that are essential for successful business today.’
Led by Steve Cook, the IML shop floor team now accounts for over 100 years of experience in PVC processing. The IML manufacturing operation runs 24 hours a day and can work to very tight deadlines, predominantly making moulded products for the access, building and allied products, housewares and packaging industries.
Specialist PVC compounder Dugdale is also set for a period of expansion this year, continuing to develop numerous PVC compounds for a plethora of applications.
Over the past five years Dugdale has invested over £2.5 million in new plant, reorganisation and the appointment of key technical staff as part of a strategy to drive the business forward through the development and manufacture of high performance PVC compounds. This period has seen three new compounding units, additional handling and dedicated development machines installed. Also added are two 60 tonne silos and a high speed mixer featuring the latest blade design and cooling technology to feed the company’s Buss Quantec 80 Ko-Kneader compounder - the first of its type to be sold in the UK. The company’s total investment since 2001 is in excess of £6 million. Dugdale has also recently taken possession of a new 22,500 sq ft warehousing unit in order to aid expansion.
On the business side Dugdale has been boosted recently by the appointment of Stuart Hope to the newly created position of Customer Development Manager. Stuart has academic qualifications in polymer science and brings nearly 25 years working experience of the PVC sector to the role at Dugdale. His most recent work was in technical service to the PVC Stablizers division of Baerlocher UK Ltd.
Both Andy Tombs and Stuart Hope will represent Dugdale at the upcoming Med-Tech EXPO show, April 20-21 at the Ricoh Arena, Coventry where the company will show its range of anti microbial grades for the medical and healthcare industries.
Investment in manufacturing facilities at Dugdale continues with the introduction of a new compounding line and materials handling system to enable enhanced manufacturing capacity. Groundwork construction has also begun on a site adjacent to the main factory that will support and equip an additional materials silo. These strategic investments are planned to be commissioned by the end of Q2, 2016.
This current phase of Dugdale expansion will take the company up to the sector’s main event in April 25-27 2017, when the UK’s triennial PVC conference returns to Brighton. The conference is the world’s largest and leading platform for the exchange of information, educational debate and discussion on PVC. Dugdale Ltd is the first Gold sponsor support for the event.
