Spectra Packaging Manufacturing Plant Expansion, Suffolk, United Kingdom

spectra manufacturing plant

Spectra Packaging is undertaking an expansion of its existing facility in Sparrowhawk near Halesworth, Suffolk, UK, in order to meet the increasing demand for its packaging products.

Established in 2007, Spectra previously operated from Broadway Drive also located near Halesworth. The company moved to the existing 17.4-acre site in 2011 to manufacture innovative packaging products and meet increasing customer demand.

Completion of the expansion project is scheduled for the end of 2017, while operations will start by April 2018.

Spectra Packaging's Suffolk plant expansion details

Investment in the Suffolk site is part of Spectra's long-term plans aimed at future growth. Planning permission for the expansion project was granted in 2015.

The expansion will increase the packaging plant's size by 50%, adding 24,000ft² to the existing 80,000ft². Groundwork was completed in May 2017 for foundations to install the new steel structures for the expansion.

The Suffolk site also has enough space for future expansion to include additional facilities. The current expansion will create space for accommodating three production units measuring 24,000ft² each, which are planned to be added in the future.

Financing for the expansion project Spectra Packaging facility

New Anglia Local Enterprise Partnership, Suffolk County Council, and Finance East are providing a grant of up to 20% of the total cost of the expansion project. The remaining cost will be covered through loans from banks and other financial organisations.

Details of the existing facilities at the Suffolk packaging plant

The Suffolk plant has the capacity to produce up to 100 million units a year, including 20 million closures. It also includes a decorating facility with a capacity of up to 15 million products a year. The decorating facility helps to create innovative prints using innovative print technologies such as four-pass silk screen printing and luxurious hot foil stamping.

Furthermore, the site includes several open areas, which can be used for both manufacturing and storage. A large reinforced room at the plant is used to store product moulds.

The site features a man-made pond and green spaces, which minimise the plant's environmental impact of the plant.

Equipment installed at Spectra's packaging plant

An extrusion blow-moulding line containing 0.5l machines with a capacity to produce 40 million units a year is installed in the plant. Machines can produce units in sizes ranging from 25ml to 500m and are also electric, which eliminates the risk of oil contamination.

Two injection stretch blow-moulding machines are also installed, which can manufacture mould PET containers in sizes from 25ml to 500ml.

The Suffolk plant manufactures products in various types of plastics, including high-density polyethylene (HDPE), polypropylene (PP) and polyethylene terephthalate (PETG).

"The Suffolk plant has the capacity to produce up to 100 million units a year, including 20 million closures."

In-house printing is provided by two print machines that offer latest print technologies including 360° circumference printing, Braille printing and embossed effect printing.

Co-extrusion to produce packs with two or more layers of plastics is also available at the plant. In addition, the plant offers injection moulding for closures, overcaps and reducing plugs for the range of containers offered by Spectra.

In-house tooling facilities at the plant provide a range of custom designs of both containers and closures. The designs are continuously reviewed and new ones are added to keep-up with the latest market trends.

Innovative packaging solutions from Spectra Packaging

Spectra provides a range of packaging solutions for customers of the toiletries, cosmetics and personal care sectors from initial design to decorative finishing. It has provided packaging solutions to established brands such as Liz Earle, Body Shop, Elemis, Bamford, Boots, LF Beauty and Unilever.

The company's move to the new Suffolk site subsequently included the installation of new equipment in 2016, as well as recruitment of qualified personnel.