RGE – NEWS AND UPDATES

Alongside product design, toolmaking and injection moulding, RGE offer a range of additional services to compliment injection moulded products.

- Labelling
RGE are able to offer a variety of labelling and branding techniques, including the automatic application of self-adhesive labels, which is available on many injection moulded parts. This service allows us to meet requirements such as barcode labelling, or extra identification for each product as it passes through the quality checks and assembly stages.

- Printing
Detailed markings, usage instructions, and even graphics can be applied to cooled components using computer-controlled pad printing (tomography), which offers a premium finish to any product. Simple decorations such as company logos and product markings can also be applied through the application of hot-foil blocking, usually during the cooling cycle of the plastic injection moulding process.

- Assembly
RGE are able to perform linear vibration welding or ultrasonic welding, and our expertise stretches across many welding applications. We produce complex base components using linear vibration welding, which joins a lower and upper part with a watertight welding joint. This creates stable and accurate complex components. These components are then used in products that require reliable, durable, and long lasting parts, such as tumble driers.

- PU Moulding for Furniture
RGE has in-house PolyUrethane production capabilities, used for making soft touch arm pads. We are able to manufacture bespoke designs of arm pads competitively and quickly, with high quality parts manufactured at our factory in the EU.

- Fabric Mesh Inserting for Furniture
RGE is now able to assemble mesh inserts in-house. RGE Baltic facility has recently added assembly lines capable of assembling the fabric mesh into the backs and seats of office chairs, allowing us to provide the finishing touches to injection moulded furniture and offer an important service when producing office furniture.

- Upholstery for Furniture
After growing demand for upholstery for seats and chair backs, RGE works with a network of highly skilled upholstery specialists in the EU. RGE can now mould, assemble, and upholster furniture to the highest quality. When used with our Mesh Insert services, RGE are able to apply all the finishing touches to your injection moulded furniture in-house, simplifying the process and overseeing your project from start to finish.

- The Regrind Centre:
Following the launch of our in-house recycling facility last year, RGE are now able to buy back any extra stock or old products to be recycled back into material which can be reused in the production of new product or goods parts. The centre is capable of processing PP, ABS, PA, TPE, and PBT + PET, and will be expanding to grind other plastics as they become available.
 

For over 50 years, we have manufactured high quality plastic injection mouldings for our international client base, taking on a variety of projects and expanding our capabilities around the world. During that time, RGE has grown to become one of Europe’s leading suppliers of plastic injected parts, and continue to expand with the help of continuous investment in the latest technological advancements to stay at the front of the field. RGE is able to supply our clients with everything from high volumes of finished injection moulded products, through to small and large injection moulding parts, classed as mouldings of 2kg up to a maximum shot weight of 20kg. With many advantages over other plastic moulding processes, injection moulding allows products to be produced in complex and intricate detail that would otherwise be too costly or difficult to make, with the capacity to manufacture multiple parts at the same time.

Our facilities across the world make use of the latest advancements in automation and robotics, allowing us to deliver an extensive range of high quality products of various sizes, across a wide range of industries. RGE is home to over 150 injection moulding machines in our factories across the UK, with a clamp force capacity ranging from 25 tonne to an impressive 3150 tonne lock. Most recently, we have installed a new Negri Bossi NOVA 500T 4250 at our Whittlesey factory. This investment not only aids our commitment to becoming more environmentally sustainable due to its energy efficiency, but with the use of our Thingtrax system, allows our production line to run more efficiently. This helps us to meet lead times and provide high quality parts, whilst using less energy. RGE’s long term plans to investment in new machinery and equipment will allow us to meet the needs of our customer base and welcome in new clients, whilst working to use less energy and produce less waste.

RGE factories operate 24 hours a day, 7 days a week, producing over 100,000 injection moulded parts per week and approximately 6 million large parts per year. Producing such large quantities enables us to match our customers’ needs, whilst maintaining an exceptional level of customer service and quick turnaround times. Our manufacturing capabilities gives us the competitive edge – our clients receive precision mouldings at cost effective prices every time.

Enquire today, or find out more about our injection moulding capabilities here and here.

Since our start in 1965, tool making has been at the heart of what we do. Partnering with customers from a variety of different industries, we complete more than 200 injection mould tooling projects each year, providing turnkey tool and mould making solutions across numerous sectors.

Our vast industry knowledge and experience means we are able to manufacture injection mould tooling with multiple cavities, gas injection, fast cycling, bi-injection, and over-moulding moulds. We use the latest technology to utilise the best of both the surface and solids systems of CAD modelling. We also have our own toolroom located at the RGE Whittlesey site, giving us the ability to service mould tools and run production under the same roof.
 

The toolmaking process

Our engineering team works closely with our design engineers to ensure that all of our high quality tools are tried, tested, and made to your exact requirements every time. Prototypes are made to test the functionality of each design and allow us to work on the tooling requirements for the project. Working with RGE toolmakers at our facility in China, tool designs are generated and sent back to us to validate before work begins.

A number of different tests are carried out on the tools before the manufacturing process begins. Test mouldings are made to allow us to check that the tool works correctly, and to test the mould flow in practice. This can sometimes lead us to make changes to the tools, or changes to the design of the product itself to ensure the best functionality. T1, T2, and T3 samples of the product are manufactured using the tools, and then approved by the customer ahead of production. RGE works closely with the customer, reviewing every step and each sample before production progresses. The constant reinvestments we have made to this crucial area of the business have seen our tooling capabilities expand as we take on more varied and complex projects.

We produce high quality tools at very competitive prices. Enquire about your project with us today

With continued investment in our product design and research facilities, RGE have been able to push the boundaries of what can be achieved with plastic injection moulding. Product design is the first stage of the production process, bringing the customer’s idea or concept into a fully formed vision, with a plan in place to bring it to reality. We work closely with each customer to meet their needs and requirements, and provide the most effective and efficient plastic parts and tooling possible.

The design process

With our decades of experience and involvement in complex and innovative projects, we understand that attention to detail is paramount. Our product design engineers are capable of creating designs from scratch, but often build upon the customer’s initial ideas or help to adapt any previous designs that the company may have commissioned, in order to create designs that are suitable for the injection moulding process. Our Design Manager Mark Temple often attends meetings with clients’ in-house design teams or design agencies that they have previously used, and visits their facilities to view other products they have produced to get a feel for their style. Following the initial sketching and 3D modelling, our engineers, including Senior Design Engineer Alan Ramscar, use a range of in-house software packages to produce SLA, SLS, and rapid modelling.

Following meetings with clients, revisions and changes to the initial designs are made until the client is ready to move the product to prototyping. We are able to create prototypes in any nylon, polypropylene, or ABS material. Our team maintain a strong relationship with each client during the process, and ensure that the final designs meet their vision before prototyping begins. Find out more about our design and engineering process here. 

Industry Experts

Our product design engineers have conceived, designed and production engineered some extremely popular and recognised products available worldwide:

• High end and high volume office furniture
• Retail & food produce containers
• High volume, low cost home goods

Enquire today.

Founded in 1965, RGE has nearly 60 years of injection moulding expertise, specialising in tooling, precision plastic injection moulding, and development engineering. During that time, we have grown to become one of Europe’s leading suppliers of plastic injected parts, and are continuing to grow with the help of investment in the latest technological advancements.

What do we offer?

As a full service company, we offer design, printing, welding, upholstery, and assembly services, alongside our vast experience in injection moulding, tooling, and product development. With facilities in the UK, Lithuania, and China, RGE are able to operate on a global scale and take on large scale projects, as well as smaller projects closer to home. RGE offers a worldwide service, taking on a huge variety of projects from office furniture, material handling, home goods, white goods, technology and electrical products, and more.

All about quality

Providing high quality parts and services is at the heart of what we do. Our team work closely with you to meet the quality requirements of each mould tool and end product, and oversee each step of the process, taking projects right the way through from concept to finished product. With competitive lead times and large investments being made to improve efficiency at our factories, RGE are committed to providing the best service to foster long lasting relationships.

Find out more about the services we offer.

Introducing our extended range of MultiNest Crates: now available in Lime Green, Light Grey, and Cornflower Blue. These colours join our original range, along with the recently added pink and orange. Staying organised is easy with all the great MultiNest features you know and love. The new colour range has been designed with the home or small business in mind, to complement any interior. Nestable when not in use, and stackable to maximise storage, the MultiNest crate is the perfect multifunctional storage solution.


Storage crates have become a great way to store items in a more stylish way. With endless possibilities for use, our versatile multifunctional crates can be used anywhere around the house:
- The perfect size for under the bed storage
- Store food safely with ventilation holes and food grade material
- Tidy away toys in your living room with an aesthetically pleasing finish
Our new, eye catching colour range makes the MultiNest even better suited for use around the home, becoming part of the décor as well as a practical storage solution.


The MultiNest crates are high quality, robust, and cost effective. Collapsible bale arms allow the crates to be stacked on top of each other, or nested within each other when not in use. Our extended range of colours feature easy label removal texture, and are operational between temperatures of -10C and +50C. The MultiNest was designed with environmental responsibility in mind – made from plastic injection moulding, there is little to no waste in the entire production process and the crate can be fully recycled.

As part of RGE’s commitment to becoming more environmentally sustainable, further investments have been made to our Whittlesey factory to improve our energy efficiency. A new Negri Bossi NOVA 500 T 4250 has been installed to replace the old V430, the latest of several new machines that have been installed at our Whittlesey factory. The new injection moulding machine is far more energy efficient and consumes only 8 Kilowatts Per hour, compared to the 80 Kilowatts Per Hour used to power the old machine. The NOVA is fitted with a variable motor speed so that it is not permanently running at high power usage, as old machinery does.

The machine primarily is used to produce containers, closures, and general small and medium size parts for a variety of industries. Currently the new machine is being used to produce waste bins and lids. By investing in more modern machinery, RGE is committed to increasing our energy efficiency whilst ensuring the best quality for the products we produce.

Our Production planning team now refer to machine energy efficiency by means of RGE’s Thingtrax IT system before agreeing on daily production runs. This is planned by selecting the most energy efficient machine when scheduling tool changes to meet customer requirements. This helps our factory to run more efficiently, allowing us to meet lead times whilst using less energy.

Following the installation of solar panels at our Whittlesey site in 2018, we have generated 1,209,639 Killowatts of energy as we move towards a more sustainable future for RGE. Plans are now in place to fit solar panels across the rest of the roof, with the project to be completed by March 2023. Find out more about our previous solar panel installation here.

Introducing the Temple chair. RGE’s latest task chair, designed by our head designer Mark Temple for use in both the office and home.

The chair expertly combines ergonomics and style. Its sleek shape and modern XO base blend seamlessly into the home or the office. The meticulously designed back, with its unique central column, and innovative moulded seat foam provide comfort and support.

The Temple chair is recyclable and made from recycled materials.

Available early 2023

Following the launch of our in-house recycling facility last year, RGE have continued to invest in the Regrind Centre, most recently with new machinery to increase our recycling capabilities. Our expanding range of machinery allows us to take on more and more plastic waste, recycling old parts and products into material to be reused.

A new IRS 1500 Single Shaft Shredder has been installed, able to break down plastic material more easily. Previously, large plastic parts were cut with an electric hand saw in order to fit into the Cumberland Granulator, which took up a lot of time and was greatly reducing the output of the granulator. The new shredder will vastly improve this process and will allow the Regrind Centre to operate more efficiently. This investment will allow for a greater output, which in turn enables RGE to take on larger workloads and more plastic waste from other companies.

The shredder will be fed through a conveyor belt system of about 10-15 parts at one time. The machine will then break the parts down into 50mm chunks which is then piped into the Cumberland Granulator, which breaks the material down further into 10mm size pieces. These pieces can then be used in the production of goods parts, or are sold back into the market.

Better piping has also been added to the Cumberland Granulator, and a dust extraction unit has been installed to greatly reduce the amount of dust from entering the finished bags of reusable material.

RGE have also added a GSL300/800 Zerma Granulator, which will greatly increase the number of parts that can be regenerated back into usable materials, and will help the facility process more plastic waste.

Better piping has also been added to the Cumberland Granulator, and a dust extraction unit has been installed to greatly reduce the amount of dust from entering the finished bags of reusable material.

RGE have also added a GSL300/800 Zerma Granulator, which will greatly increase the number of parts that can be regenerated back into usable materials, and will help the facility process more plastic waste.

Currently, RGE are working on plans to move the bag extraction areas into their own rooms in order to reduce the dust and noise levels. We are excited to see the Regrind Centre continue to grow and improve as we are able to process higher levels of plastic waste. Find out more about the Regrind Centre here.