Award Recipients

Following a 90% growth in international sales, Suffolk-based FRP mouldings manufacturer, Broadwater Mouldings Ltd, has been awarded The King’s Award for Enterprise for International Trade.

Broadwater, a subsidiary of the Betts Group, formed in 1971 as a contract moulder operating alongside its sister company, Hatcher Components. Following increased demand, in 1977 Broadwater acquired a boat building business in the market town of Diss in Norfolk and began manufacturing green junction boxes for British Telecom and parts for the bus-building industry, alongside commercial vehicle components for Hatcher.

Fast-forward 10 years to 1987 and the company acquired another factory in Garboldisham to run alongside Diss. It was at this point that Broadwater began manufacturing bodywork panels for an international leading producer of medical equipment, in addition to the commencement of materials handling equipment (Spiral Chutes) for the British Post Office. Additional capacity was urgently required in order to meet this demand.

As the company’s reputation and customer base grew, in 1994 Broadwater purchased a facility in Horham, Suffolk, and operations from both Diss and Garboldisham were relocated there. During this time more medical equipment work was commissioned for radiotherapy treatment machines.

In 2009, the opportunity arose to acquire a newly built composite manufacturing plant in Beccles. All operations were swiftly moved from Horham, where new contracts were formed in the construction equipment, agricultural, motorsport and motorhome sectors – and that acquisition brought with it faster manufacturing technologies for higher volume work.

In 2010, Broadwater won a large chute contract and again extra space was needed. Management made a temporary arrangement with the new owners of the former site at Horham Business Park to use the facility for approximately six months, just to complete the contract… and they never left.

An innovative approach
Since the privatisation of Royal Mail, Broadwater owns the trademark in the UK and Europe for ‘Safeglide’ Spiral Chutes. These have since found their way into distribution hubs for the likes of Amazon, DHL, DPD and Evri. They are also used in baggage handling systems in airports across the globe. ‘Safeglide’ Spiral Chutes form a fundamental part of Broadwater’s portfolio.

The company continues to innovate in FRP manufacturing methods for various market sectors and, in 2023, purchased and commissioned a thermoforming machine. A purpose-built unit was erected on the Beccles site to accommodate the large machine, aimed at expanding the company’s customer base even further. The new equipment allows for the use of fully recyclable materials, as well as recycled, that has broadened the range of materials on offer to existing customers and opened new doors to different markets and public transport vehicles.

A team effort
Broadwater currently employs over 180 people across both sites, two of which are still with the company after joining in 1978. Group Managing Director, Matthew Herbert, says: “This award recognises the achievements of the entire Broadwater team, some of whom have worked in, and have been dedicated to, developing the business over decades. We have worked extremely hard to achieve the growth we have seen; there have been many challenges along the way but we have always overcome them one way or another.

“Every person working at both our manufacturing sites have helped meet those challenges. I am extremely grateful to every one of our people, and proud to represent them. I am looking forward to continuing with them to build on our success.”

Matthew joined the company in 1986, becoming a Trainee Laminator in 1987. In 1989 he accepted the position of Assistant Production Manager. In 1992 he became Quality Manager, during the adoption of the company’s then new Quality Assurance System BS5750 (now ISO 9001). Following the acquisition of the Horham site in 1994, he was tasked with running the factory as General Manager. Fast-forward to 2002 and Matthew was appointed to the role of Works Director, eventually becoming MD in 2006.

Quality assurance
Following Matthew’s lead in quality assurance, Broadwater also received ISO 14001:2015 accreditation, recognising that its operations have an effect on the local, regional and global environment. The company regards the proper management of the environmental aspects of its business activities as mutually beneficial to all interested parties and is committed to continuously improve its environmental performance and prevent pollution.

In 2014, Broadwater was awarded accreditation to the Suffolk Carbon Charter. The company defines its environmental objectives and targets annually. Regular progress monitoring takes place during monthly management meetings and a review takes place every six months, during which the objectives and targets are re-assessed.

Broadwater employs a number of moulding techniques, including Hand Layup, Spray Layup, LPPM (Low Pressure Press Moulding), RTM (Resin Transfer Moulding), RTML (Resin Transfer Moulding-Light), RI (Resin Infusion), and Polyurethane Low-Density Foam (foam cores for RTM, RTML, Vacuum-Forming and LPPM).

Closed mould processes as listed above produce a smooth semi-cosmetic ‘B’ surface. Many of their customers prefer this, particularly where the end user will see the ‘B’ surface of the moulding. One of the company’s USPs is the ability produce and supply mouldings and assemblies with a surface finish which does not require painting or post mould coating.

Thermoforming, also known as vacuum forming, offers many of the same benefits as FRP. The wider choice of materials and scope of their new machine opens up more possibilities for more sectors, whilst being able to economically cater for projects large and small.

Crucially, Broadwater also provide a full tooling service across the board, taking them from a contract moulder to offering a fully bespoke design & manufacturer service. This has led to significant improvements and innovations in existing moulding techniques, all of which benefit both company and customer.

Safety is paramount
With all the above moulding practices on board, the company has a strong emphasis on a safe working environment. After successful audits, Broadwater was awarded the ISO 45001:2018 Safety Management System Standard accreditation. Developed by leading trade and international standard bodies, ISO 45001 provides a framework for organisations to instigate efficient and effective management of health and safety.

Finance Director, Mags Humphrey says: “Broadwater’s main market is Europe, although its products are in daily use worldwide. Our market position has changed from purely a parts supplier to a strategic design partner for our main customers and we have significantly expanded our manufacturing capabilities and processes in recent years. To receive this award is a massive honour and is a hugely respected measure of excellence, which is recognised both in the UK and abroad.”