NEWS AI automation boosts efficiency and growth at manufacturing site
Polypipe Building Services has enhanced manufacturing efficiency, productivity and sustainability through a major programme of automation investment at its production facility in Aylesford. The manufacturer now uses fully automated lines across key areas of the site, integrating robotics and AI-driven quality inspection systems as part of a long-term strategy to improve operational performance and address industry-wide skilled labour shortages. With this new level of
automation, Polypipe has been able to meet its growth aspirations, without increasing staffing levels and the facility, which operates on a 24-hour, five-day production cycle, has increased output and improved responsiveness to fluctuating demand. Recent investment includes £1.5 million in automation technology, alongside further investment of £3 million in moulding machinery and £2.5 million in extrusion technology. The manufacturer has implemented automated systems using six-axis and Cartesian
robots, allowing operators to oversee production processes that deliver finished products with minimal manual intervention. As a result, Polypipe has improved the consistency and quantity of its drainage and water supply products while maintaining existing workforce levels. Advanced vision technology, including the new IV4 AI camera, has also been introduced to support quality assurance. The system automatically counts parts and detects issues such as dimensional variation, ovality and moulding defects, helping ensure products meet quality standards before being packaged by robotic handling systems. The introduction of automation has significantly improved labour efficiency across
production lines. Where processes previously required one operator per machine, production can now typically be managed at a ratio of one operator to four machines. This has enabled the business to redeploy employees into higher-value technical and operational roles. Ned Seale, Tooling and Automation Manager at Polypipe Building Services, said:
BSRIA launches Guide of Guides to aid navigation of building services industry guidance
BSRIA, the science-driven independent organisation providing practical guidance and commercial solutions for the built environment, has launched BSRIA Guide of Guides, the guide to building services guidance. The BSRIA Guide of Guides is a new online directory designed to help the building services community cut
through a complex guidance landscape. It brings guidance from key industry associations and publishers together in one place, curated, organised and easy to navigate. Building professionals can now spend less time searching and more time delivering great work. As well as providing a speedy solution to finding something specific, expert indexing allows users to readily
explore wider guidance. Publications are indexed according to themes impacting the industry, building service categories and project stages, facilitating industry knowledge sharing and alignment. Kim Burgess, Director of Professional Services at BSRIA, added: ‘As guidance continuously evolves and AI driven
search and SEO make sourcing information online more convoluted, the risk of relying on outdated, inaccurate or incomplete advice also increases. This platform, shaped by valued member feedback, makes it faster and easier to find accurate guidance when it’s needed.”
“This is an exciting industry first which will support building services professionals in ensuring that best practice becomes standard practice. It demonstrates that, as ever, BSRIA is committed to finding practical ways to benefit the industry, our building stock, and ultimately those that will use the spaces we create.” The directory is currently available to BSRIA members and full-time students enrolled on building-services-related university courses. BSRIA aims to expand access and additional
features according to user feedback and demand, established in the tool’s initial version. Publishers with relevant guidance are invited to contact BSRIA to discuss inclusion in future updates.
“Automation is helping us respond to growing demand while maintaining quality and supporting our workforce. By integrating robotics and AI inspection technologies, we are improving production consistency, reducing waste and allowing teams to focus on more technical, value-adding activities.”
“While the initial investment can be significant, automated systems can deliver long-term operational benefits through improved efficiency, quality and resource optimisation.” Automation is part of Polypipe’s overarching strategic move to drive efficiency,
productivity and sustainability across its operations. Since the transition, the manufacturer has recorded reductions in energy use and material waste. Polypipe is continuing to expand its automation capability through workforce development, including the recruitment of an automation apprentice and plans to further grow its engineering team. The next phase of automation investment is expected to focus on the fabrication department, where manual processes are currently used to manufacture prefabricated pipe systems.
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12/09/2025 13:28 14/10/25 10:30 BUILDING SERVICES & ENVIRONMENTAL ENGINEER APRIL 2026 5
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