Lesney Industries Ltd

Plastic Injection Moulding

With an annual manufacturing capacity for over 20 million plastic injection mouldings, we’re able to cater for almost any volume requirement. And with a range of state-of-the-art injection moulding machines at our disposal, we can produce plastic moulds of virtually all shapes, sizes and complexities, using all the common materials (PP, HPDE, GPS, ABS, etc.) as well as various engineering grades (PA, PBT, TPR, PPO, POM, etc.). Lesney Industries’ engineers can advise you on the most suitable thermoplastic material for your application.

We serve a number of industries, including automotive manufacturing, electronics, telecommunications and engineering, as well as the white goods sector. 

Plastic Injection Moulding Plant List

At our manufacturing facility in Harlow we have 18 plastic moulding machines ready for service, giving us an annual capacity for over 20 million parts. They include:

• 1 x 400 tonne Cincinnatti Milacron Vista Machine with a VEL Micro-Processor Control Unit (Includes Process SPC Package). Fitted with a Pressflow Pacer Pick & Place Robot & Parts conveyor. 
• 1 x 400 tonne Negri-Bossi Machine with a VEL Micro-Processor Control Unit (Includes Process SPC Package). Fitted with a ENM Pick & Place Robot.
• 1 x 250 tonne Demag Ergo Tech Machine with full Micro-Processor Control (Includes Process SPC Package). Fitted with a Pick & Place Robot.
• 1 x 200 tonne Arburg 520C 2000-675  All rounder Machine with Selogica Control Panel.
• 3 x 150 tonne Sandretto 1500/612 Machine with full Micro-Processor Control (Includes Process SPC Package).
• 1 x 95 tonne Battenfeld Moulding Machine.
• 1 x 80 tonne Twin Shot Arburg 420M 800-225
• 2 x 80 tonne Demag Ergo Tech Machines with full Micro-Processor Control (Includes Process SPC Package). All fitted with Pick & Place Robots.
• 2 x 50 tonne Demag Ergo Tech Machines with full Micro-Processor Control (Includes Process SPC Package).
• 1 x 50 tonne Arburg 320C 500-250  All rounder Machine with Selogica Control Panel.
• 2 x 50 tonne Arburg Moulding Machines.
• 1 x 40 tonne Sandretto Moulding Machine.
• 1 x Boy 22D Moulding Machine.

Zinc-Diecasting

Every year, the Lesney foundry produces over 10 million quality-assured zinc castings – so we know a thing or two about volume production! But whether you need large volumes or small batches, we’ll be happy to provide a high quality, low cost solution that meets your production requirements. State-of-the-art die casting facilities enable us to produce zinc components to the closest tolerances, both quickly and cost-effectively. 

Meanwhile, an integrated machine and trim department enables us to carry out a variety of finishing tasks, including turning, milling, drilling and tapping. 

Zinc Die-Casting Plant List

The Lesney zinc die-casting foundry is equipped with a range of modern machines capable of performing a variety of tasks. They include:

• 1 x Meltec Remelting Furnace, capacity 500Kg Zn/hr with metal transport furnace and scrap conveyor.
• 1 x Frech DAW200S-RC Hot Chamber Die-Casting Machine with 200 tonne locking force, Data-Vario Processor controller and 3-Stage injection unit. Complete cell with Gripmat pick & place Robot and 20T Hare Clip Press.
• 1 x Frech DAW125S Hot Chamber Die-Casting Machine with 125 tonne locking force. Data-Vario Processor controller and 3-Stage injection unit. 
• 2 x Frech DAW125SBC Hot Chamber Die-Casting Machines with 125 tonne locking force. SBC 2.0 controllers and 3-Stage injection units. 
• 1 x Frech DAW80C Hot Chamber Die-Casting Machines with 90 tonne locking force. Data-Logic Processor controller and with injection control package, tool data storage and cycle time diagram. Includes weighing m/c to monitor m/c safety and quality of parts.
• 1 x Frech DAW50A Hot Chamber Die-Casting Machine with 60 tonne locking force. SBC 4.0 controller and 2-Stage injection unit.
• 2 x Frech DAW20A Hot Chamber Die-Casting Machine with 24 tonne locking force. SBC 2.0 & SBC 4.0 controllers and 2-Stage injection unit.
• 1 x Mk 28 Hydraulic Hot Chamber Die-Casting Machines both with a 200 tonne locking force, full Micro-Processor controls and 3-Stage injection units.
• 5 x Mk 7 Hydraulic Hot Chamber Die-Casting Machines all having a 170 tonne locking force, full Micro-Processor controls, High & Super High Velocity Pressure Intensifiers and 2-Stage injection units.

Technical Services

Our Technical Services Department deals with the design of plastic injection moulded components and zinc castings. This includes the modification of existing designs to suit the manufacturing process. Our company policy is to design quality components that are suitable for manufacture right from the conceptual stage, ensuring that our customers’ expectations and our own manufacturing requirements are fully satisfied.

Quality Control Department

Our quality control procedures are accredited to ISO 9001:2008, giving you complete peace of mind. To test, check and inspect components we use the following equipment/software:

• 1 x Mitutoyo Type M544 3-Axis CMM & a Renishaw MRP-2 Measuring Head with interchangeable Stylii with Cosmos Operating system.
• 1 x Trimos Electronic Height Gauge.
• 1 x Mitutoyo Projector with Digital Micrometer Axis Readouts.
• 1 x Light Box for Colour Comparison.
• 1 x Seat of ‘Mini-Tab’ SPC Software.
• 1 x Seat of ‘Lighthouse’ SPC Software.
• Plus a good supply of standard metrology equipment. 

Die-casting or Moulding Budget Quote

To get a quick budget quote for a die-casting or plastic moulding project, please supply us with the following information:

For new tooling quotes:

• Component drawing and/or 3D CAD file.
• Material and grade required.
• Quantity needed (per annum) and batch size requirements.
• Any additional protective or aesthetic finishes required. 
• Project timeline. 

For transfer tooling quotes:

• Sample casting or moulding (if possible).
• Type and size of machine the tool currently runs on.
• Number of cavities.
• Details of secondary operations performed.
• Any quality issues associated with the current products. 

Call our Business Development Director today on 07771 887249.