Updated: Wednesday the 23^rd of May, 2012 Rutland Plastics Ltd

With over 50 years of experience and the capability to manufacture a full range of plastic mouldings as small as a few grams or as large as 48 Kg in a wide variety of thermoplastic materials, we can help you streamline your production processes with the latest injection moulding technology.

We offer complete plastic injection moulding services, from initial design and mould making to injection moulding and assembly, as well as machining and packaging if required.

We are specialists in the moulding of large and thick section plastic mouldings as well as in the electrofusion process. We also offer innovative gas assisted injection moulding.

We are ISO9001:2000 and ISO14001:2004 accredited. We offer individual attention, high quality standards and continuity of supply while minimising environmental effect. 

We invest heavily in the latest injection moulding equipment, and we believe in the same level of investment in the training and development of our employees. We have been recognised as achieving and surpassing the Investors in People standards since 1999. We offer apprenticeships, deliver NVQ courses and assessments, and support higher education of our staff including HNC/D, Foundation and BSc degrees as well as industry bespoke training courses in disciplines including engineering, polymers and injection moulding.

This investment results in a highly skilled workforce capable of carrying out the most technically demanding injection moulding work to the highest standards.

Design

Plastics injection moulding requires a specific approach, and our expertise means you get the most suitable design from the outset. 

We work with you to make the best choices of plastic materials and physical shape to result in optimum ease of production, cost efficiency and performance. 

Working with us from the initial concept through to the injection moulding design stage using 3-D CAD, and finally to the making of the injection mould tool saves you time and money by eliminating the need to use expensive external design services.

Prototypes can be arranged through our partnerships with prototyping services suppliers.

Tooling

We offer cost-effective mould-making through both in-house plastic mould and tool die manufacture as well as manufacture by subcontract toolmakers with whom we have long-established working relationships. 

We manage subcontract tooling as in-house, and our experts only approve a subcontract injection mould when they are sure of optimum performance to our specifications. We also offer the option of overseas manufacture to UK specifications for suites of moulds or larger tools.

We provide free tool maintenance during the working life of all injection moulds manufactured by us or one of our partners while we are the appointed moulder. 

In the event your plastic mould tool requires emergency attention, we can ensure minimum disruption to your production process thanks to our on-site facilities which allow us to make tooling modifications quickly and economically. 

Moulding

Our extensive range of modern injection moulding machines gives us the capacity to produce plastic mouldings weighing up to 48 Kg, with particular expertise in thick sections; in some cases in excess of 100 mm. This versatility enables us to meet most custom moulding requirements using cost-effective production methods.

Our computerised system provides full traceability and flexibility, allowing us to manufacture to order or work to schedules. We can offer the best price and maximum flexibility by manufacturing plastic mouldings in larger quantities, holding a balance in stock for call-off as required.

We produce plastic components for a wide variety of industries, so our injection mouldings are manufactured in many different thermoplastic materials, including prime or recycled / reprocessed, glass or talc-filled, or unfilled. Additives such as anti-microbials or flame retardants are available as well. 

Machining

Machining or assembly with other components is often required to complete the manufacture of plastic injection mouldings. We have the capabilities and expertise to provide finishing touches such as multi-component assembly, trimming, sonic welding or machining to tight tolerances, eliminating the need to source a separate subcontractor. We may even be able to produce your complete product ready for onward shipment to your customer without further work or re-packaging in some cases.

Thermo Plastic Materials

Many different thermoplastic materials can be used in injection mouldings. Groups of plastics have different performance levels, and blends of different materials can sometimes be used to take advantage of the best performance properties of two individual materials. 

Fillers such as glass or talc can provide additional strength in many cases, and additives for increased flame retardancy, UV stability or anti-microbial properties can also be used. 

The materials we can use include polypropylene, acrylic, polyethylene, polystyrene, nylon, acetal, polyvinyl chloride, polyurethane, and polyesters.

Electrofusion

We have patented an electrofusion manufacturing process that allows a simple and rapid method of joining plastics. 

For example, in the case of joining water and gas pipes by electrofusion, we bury a lead-in wire under the coil winding used to fuse the pipe ends together when current is passed through. This reduces the risk of shorted wires during the welding process, which is a failure commonly associated with similar fittings. 

We have also developed special sleeve bonding systems for joining insulated pipes as well as fittings that permit flanges to be joined to the sides of plastic vessels.

Gas Assisted Moulding

Gas Assisted Injection Moulding (GAM) is a relatively new plastics injection moulding technology in that offers opportunities to reduce costs and improve the quality and appearance of injection moulded components.

In GAM, pressurised nitrogen is introduced to the mould cavity at a set time during the moulding cycle. Cost reductions are realised due to reduced material quantity and production cycle times, as well as the ability to use single moulds and a smaller moulding machine. Finished products have fewer flow marks, reduced distortion and sink marks are eliminated. 

GAM allows designers to use more imagination in the creation of injection mounded components as variable thickness sections can be included, and several components can be combined on a single part. 

Plant List

Our extensive range of modern micro-processor controlled injection moulding machines, many with robots, are supported by up-to-date plastic moulding techniques.

This means quicker tool changes and the efficient production of consistently high quality plastic components. Whether you require a small plastic part weighing only a few grams or a complex component weighing several kilograms, we can provide a cost-effective plastic injection moulded solution.