Editor’s Interview
“We had moments when some of our core retail went up, but in the main, we were still heavily involved in foodservice and we still did a fair bit of work with the airlines,” Mr Hill said. “When the lockdown announcement was made, 40% of business planned was definitely not going to happen. It was a very sobering moment. We had a lot of investments lined up pre-COVID and everything was put on hold
Mr Hill said that furlough was a lifesaver for many businesses.
“For us, it gave us breathing space,” he said. “2020 was pretty dismal.”
During the pandemic, KPL designed and manufactured as one-piece visor.
“We looked at something that could be mass produced in one piece very quickly and serve a purpose,” Mr Hill said. “By the time we were in the final throes of our negotiations, the rest of the world had caught up.
given our size of business, it’s a massive investment, but it’s part of our commitment to how we’re pushing the business forward,” Mr Hill said. “We’re a UK supplier, we’ve got pretty much a 100% UK supply chain, and we’re using a lot of recycled content that comes from the UK as well.” Mr Hill said that RPET accounts for 85% of material used.
“While the business is centred around the manufacturing of plastics, we are always looking for other opportunities,” Mr Hill said. “My primary function is to make the factory profitable and munch plastic through it.”
Mr Hill said that clients work with KPL for the high level of service that the business offers. “We offer a fast-track pattern service, where we can convert samples in about 48 hours,” he said. “We do fast track tooling and fast track sample drawings too.”
KPL also has an award-winning apprenticeship scheme.
“Every year we take on two or three apprentices and we can offer engineering apprentices, toolmaking and design and realisation,” Mr Hill said. “One of our former apprentices, who joined us at 16, is now running a department.” In its quest to make plastics as sustainable as possible, KPL has not only been working on improving recycled content and the recyclability of its products, but it have also looked into to how it could make it plastic products lighter and more efficient too.
“KPL’s R&D team started to look into how we could create lighter packs while still keeping them strong and fit for purpose,” Mr Hill said. “We looked at many engineering techniques in tandem with how the processes of thermoforming plastics works. The stronger yet lighter initiative is known as KPL Cirrus.
“KPL Cirrus works by creating a unique pattern in the sidewall of the container, which forms a series of many small pockets where material continually gets slightly stuck as the container is formed – this, in turn, creates stronger sidewalls with less material, thus creating a much lighter yet stronger pack.” Mr Hill said that Covid was “a struggle”.
“We pitched it at a very reasonable price and my main driver for it was I had a factory that wasn’t turning enough, and I had people that needed employment – we did sell half a million visors.” During the pandemic, Mr Hill said KPL continued supplying clients who wanted products. “Thankfully, we’re in a really strong position now and the investors are behind the business,” he said. “We’ve entered into the solar energy stuff, we’ve rebranded, we’re in the throes of doing a new website and we’re looking at new markets.” Looking ahead, Mr Hill said are challenges on the horizon.
He said: “The packaging and the plastics industry may have a headwind ahead; what we’ve got here is something to shout about, and we’re doing things right, and we’ll continue on that path.”
14
July/August 2023
www.convertermag.com
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