Guided by the mantra of ‘never turning down a challenge,’ Interplas Coatings has successfully reshored work from Asia, retained multiple high-value projects within the UK and plans to open a new high-tech facility. Jonny Williamson reports…
Over the past 30 years, Interplas Coatings has grown to become one of the UK’s leading paint spraying partners to OEMs and Tier 2 suppliers. Located in Dudley, West Midlands – the heart of the UK automotive industry – its state-of-the-art facility specialises in water and solventbased wet paint application, spraying plastic and metal components for global auto manufacturers.
Interplas’ client list reads like a who’s who of auto giants, including Aston Martin, Bentley, BMW, Jaguar Land Rover, Toyota, Nissan and Rolls Royce, to name a few. Beyond automotive, the company extends its expertise to the health and military sectors alongside a range of niche products, from beauty salon equipment to professional-grade speakers and selfserve vending machines.
Having leased the building since day one, the owners – Narinder and Avtar Kaur Mahi – marked Interplas’ 25th anniversary by purchasing the site with a £600,000 package from Yorkshire Bank. This funding kickstarted an extensive renovation programme, including reconfiguring the internal layout, installing cutting-edge new machinery, improving staff areas and modernising the exterior.
These upgrades, coupled with an unwavering commitment to continuous improvement, have yielded impressive results: a 30% increase in production capacity, a 20% uplift in productivity and a 50% boost in turnover. These gains are even more remarkable given the turbulent decade that has buffeted Interplas and the global auto industry.
Sustained strategic investments have played a pivotal role, but so has the company’s strong culture of innovation and proactive approach to challenges, said Phil Stebbings, Sales and Commercial Manager.
“While many shy away from difficult projects, we see them as puzzles to be solved. Just yesterday, I visited a customer struggling to mask a product for painting. Their product development had ground to a halt because they couldn’t find a solution. I looked at the CAD drawings and proposed a solution almost immediately. The look of disbelief was priceless. For us, it’s all about breaking down problems into manageable steps and finding a way forward.”
The power of saying yes
Interplas’ refusal to shy away from challenges has not only earned them respect but also secured substantial contracts. One of Interplas’ greatest achievements is reshoring a safety critical camera bracket from Nissan Japan to the UK.
“It wasn’t easy, let me tell you,” Phil added. “The specified paint system didn’t comply with UK REACH regulations, and the masking tolerance was just 3mm. Achieving that level of precision consistently by hand is incredibly labour-intensive.”
To overcome these hurdles, Interplas collaborated with one of its paint suppliers to develop a compliant system, and pioneered a unique vacuum-forming masking method with an innovative clipping feature to prevent paint bleed and maintain the critical 3mm tolerance.
“Previously, these parts would travel from the UK to Japan for painting and back for final fitting at Nissan UK. By streamlining the process, we eliminated a major and unnecessary supply chain loop. Every stage, from moulding and painting to assembly and fitting, now happens here in the UK, generating massive cost, time and carbon savings.”
Another triumph is Interplas’ involvement in the INEOS Grenadier 4×4 programme. Conceived to fill the gap left by the discontinued Land Rover Defender, the Grenadier was set for production in a brand-new facility in Bridgend, South Wales. But it was not to be.
A late pivot saw INEOS Automotive acquire an existing plant in Hambach, France, previously owned by Mercedes- Benz, citing strategic advantages. While most of the supply chain followed, Interplas managed to retain a crucial part of production in the UK.
“Panels for the Grenadier’s roof liner and overhead console, which houses switches and controls, posed a tricky problem. Creating them is a complex, multistage process, involving paint and graphic overlays, with no room for error.”
When others hesitated, Interplas solved the challenge by leveraging its expertise and partnerships in the printing industry.
“We receive a blank, flat moulding with various aperture sizes depending on the Grenadier model, which we spray ‘gun metal’ grey. After painting, they go to our dedicated printing partner, where the graphics are applied layer by layer, colour by colour. Panels then return to us for a full inspection before being shipped to Hambach for fitting in the vehicle.”
Interplas’ success with these panels has led to further opportunities, including nearly a dozen additional part numbers initially destined for Germany. “With INEOS launching several new colour schemes, they’re increasingly trusting us with these parts rather than looking to source everything from Europe.”
Phil is especially proud of the ripple effect in UK job creation this work is having. “Our graphics partner has hired three additional people for this project. Plus, further work we’ve won with INEOS has meant collaborating with two more printing specialists, both of whom have also grown their teams off the back of it.”
Redefining paint finishes
Interplas doesn’t just apply paint, the company is deeply involved in the entire process, from concept to completion. The team is especially keen on opening eyes to what’s possible with modern formulations, like Interplas’ satin chrome finish, which replaces traditional chrome plating.
“Many manufacturers specify chrome plating by default because that’s what they’ve always used, but our satin chrome offers the same look and feel with significant cost and environmental benefits. Whenever we present to OEMs, they are blown away.
“Proposing this alternative led to us winning additional work on the Grenadier, specifically an outer bezel in the console,” Phil explained. “It wasn’t in the original RFQ and was due to be chrome-plated in Europe. We saw an opportunity and seized it. We presented various shades of satin chrome paint to the INEOS design team, who couldn’t tell the difference in look or feel. It was another win for us, and ensured more work stayed in the UK.”
Developing a new paint is an intensive process, usually taking about four weeks. Once the OEM approves a sample colour, Interplas works closely with suppliers to create a paint system that meets the required colour, application, finish and durability.
The recipe is continually tweaked based on Interplas’ feedback regarding adhesion, hardness, spread and gloss level. Once finalised, painted panels are submitted for testing. Following approval, that batch goes into manufacture, establishing the final recipe sprayed.
Harnessing technological innovations
For spraying, Interplas blends cuttingedge paint technologies and human expertise. Recent investments include a £200,000 ABB 6-axis hollow-wrist robot. The robot’s enhanced articulation allows it to efficiently coat complex parts, reducing cycle times by 15 seconds per part. Additionally, a new wet back water wash system provides more powerful extraction, minimising airborne contaminants and improving spraying quality.
In partnership with the IT team, Phil has spearheaded the development of digital systems that have brought significant operational efficiencies. A new touchscreen programme, for example, provides instant Pareto analysis, allowing quality inspectors to quickly and easily log defects via a drop-down menu and highlight affected areas.
“Once logged, this data helps us identify which defects are most frequent or critical, enabling the team to prioritise and address the underlying causes,” Phil explained.
Another recent addition is Interplas’ paint batch management system based on a FEFO (First Expired, First Out) approach. Each batch is logged in a database and assigned a unique barcode. The system automates paint selection, ensuring sprayers use the oldest batches first. This real-time, paperless system not only optimises inventory but also allows customer enquiries to be swiftly responded to at the click of a button.
“It’s crucial we constantly look for efficiency improvements, exploit new technologies and drive forward,” added Phil. “Over the next four years, we anticipate nearly £3.6m in new business opportunities. Despite wild fluctuations in input costs, we stay competitive by focusing on managing controllable factors – reducing cycling times, optimising paint transfer and minimising waste of materials and time. This strategy ensures we meet specifications without passing inflated prices on to customers.”
Looking ahead
The road ahead looks extremely positive for Interplas, with multiple opportunities on the horizon. Having become an approved camera bracket supplier for current Nissan models, Phil is hopeful this will translate to further work on upcoming additions to the Juke and Qashqai line-up.
With Nissan UK projecting it will produce thousands each a week, such a result would represent another major boost for Interplas, with the layout and budget in place for a new three-cell robotic paint system to accommodate the work should the decision go its way.
Similarly, JLR is due to announce new additions to its line-up, with Interplas tendering bids for interior and exterior parts ranging from single-layer to four-layer paint systems. Exactly which suppliers will be granted the work is due to be announced sometime in the next six to nine months.
“I’m optimistic that decision will come our way. If it does, we intend to transform the building opposite our current site into one of the world’s most advanced painting shops to accommodate the work. Housing a new four-cell robotic system, the new facility would double our capacity, headcount and turnover; it’d be huge for us. It involves a massive volume of work but I’m confident we have the experience, expertise and drive to deliver it.”
Key takeaways:
- Interplas Coatings is a leading paint sprayer for OEMs and Tier 2 suppliers
- Strategic investments have boosted productivity by 20% and turnover by 50%
- Recently installed robotic technology has cut cycle time by 15 seconds
- Innovative satin chrome finish offers environmental and cost benefits
- A proactive approach to challenges has helped retain work in the UK
- Interplas’ successes are fuelling job creation in its supply chain
- Future expansion aims to double capacity and turnover
For more articles like this, visit our Leadership channel
