WHS Plastics has been a key player in the UK plastics manufacturing sector since 1933. With over 250 moulding machines and more than 1,700 employees across multiple sites, it is the largest moulder in the UK. Known for quality, innovation, and service, WHS has continued to grow, most notably with the acquisition of Xandor Plastics in 2023, which expanded its operational capacity and market presence.
To support this growth and maintain operational excellence, WHS needed a partner capable of delivering energy-efficient, scalable systems across its manufacturing network. For over a decade, that partner has been Summit Systems, providing tailored solutions that reduce energy consumption, improve production performance, and support WHS’s long-term sustainability goals.
Major Site Upgrades and Measurable Benefits
At the Minworth site, Summit designed and installed a comprehensive drying and loading system to support more than 20 injection moulding machines. The introduction of Vismec rotor wheel dryers delivered average energy savings of 40% compared to older twin tower systems. At Brierley Hill, a full feed and drying system improved consistency and efficiency across the entire mould shop, while a chilled water system installed at the Minworth paint plant enhanced process stability and quality.
A significant development at Minworth was the Cell Divider Project, which involved the creation of a modular central feed and drying system designed to scale in line with Jaguar Land Rover production requirements. Phase one is complete, with further expansion planned. WHS has also invested over £100,000 in advanced temperature control units supplied by Summit, achieving more than 20% reductions in cycle times and lowering scrap rates across operations.
Larkhall Cooling Upgrade
One of the most impactful current projects is at Larkhall, where Summit is replacing the outdated cooling infrastructure with a modern, energy-efficient system incorporating free cooling. The new 360 kW system is expected to deliver annual energy savings of £89,500 at full utilisation, with a 10-year saving of £895,000 and a return on investment in just eight months. Even at current operating levels, annual savings of more than £40,000 are anticipated, with ROI in 16 months. This investment will reduce energy use significantly while strengthening process reliability.
Sustainability and Operational Efficiency
Summit has supported WHS in strengthening its in-house recycling capabilities by optimising granulation and reintroducing regrind material into production. This approach has reduced material waste and lowered the company’s carbon footprint. Trials with new drying technologies are targeting up to 70% reductions in drying times, and efforts are ongoing to cut tool changeover times, further enhancing operational efficiency.
Training and Long-Term Support
Summit’s involvement extends beyond equipment supply. The partnership includes free in-house drying training, moisture analysis trials, and proactive annual servicing across multiple sites. These initiatives have ensured reliable equipment performance, reduced downtime, and extended the lifespan of both new and legacy systems, some of which have been in operation for over 30 years. This proactive approach proved invaluable during challenging periods such as the automotive downturn and COVID, allowing WHS to maintain production while deferring capital expenditure.
Looking Ahead
Summit is currently working with WHS on a new process cooling project at the Pickering site to address cycle time challenges. By improving water temperature control and leveraging existing infrastructure, the solution will enhance production efficiency and support WHS’s continued focus on sustainable manufacturing.
“Our engagement with Summit has exceeded all expectations. The improvements they recommended were strategic, practical, and results-driven. We’ve seen measurable outcomes that align perfectly with what was promised, proving their expertise and commitment to delivering real value.”
The partnership between WHS Plastics and Summit Systems demonstrates how long-term collaboration can deliver measurable results. Through carefully planned projects, energy-saving technologies, and ongoing technical support, Summit has helped WHS achieve significant cost reductions, efficiency gains, and sustainability improvements across its sites, supporting its position as a leader in UK plastics manufacturing.
