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A market-leading manufacturer of high quality thermoplastics from prime and recycled polymers
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Testing, developing and analysing engineered polymer for a range of specialist applications
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Unique 'closed' and 'open loop' plastic recycling and waste management solutions
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Pioneers in sustainable innovation and polymer technology, compounding and recycling since 1965
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Undisclosed challenges and considerations that mould tool sellers face

In the ever-evolving landscape of sustainable manufacturing, Luxus stands at the forefront as a pioneer in recycled plastic compounding for nearly six decades. With a commitment to innovation and environmental responsibility, Luxus has become a trusted partner for companies looking to integrate recycled plastics into their manufacturing processes. However, there are critical aspects of the compounding process that often go unnoticed, particularly when it comes to the specifications of mould tools. In this blog post, we uncover the undisclosed challenges and considerations that mould tool sellers may not always share, shedding light on the intricacies of recycled plastic compounding. 

Hot Gates: Size Matters, but Shear Matters More 
One of the key considerations in mould design is the size of hot gates, which can significantly impact waste reduction. Smaller hot gates may seem like an eco-friendly choice, but there's a hidden trade-off: increased shear. Shear, in the context of plastic compounding, refers to the degradation of the polymer during processing. The finer the hot gates, the higher the shear forces, leading to potential issues such as physical imperfections like splashing and silvering marks. 

We understand the delicate balance between waste reduction and material integrity. With 59 years of experience, we can navigate these challenges and develop customized solutions that meet your specific needs. By knowing your requirements, we can specify materials and create grades that optimise performance while minimising the impact of shear forces. 

The Complex Conundrum of Melt Temperature 
Complex mouldings often demand higher melt temperatures, but this comes at a cost – reduced physical properties like impact strength. Some mould tool designers may specify running materials at hotter temperatures without fully considering the consequences. Luxus materials can be tailored to accommodate higher temperatures, but again, this requires collaboration and knowledge sharing. The more we know about your project's intricacies, the better equipped we are to design materials that strike the right balance between complexity and performance. 

Residence Time: A Crucial Factor in Degradation: 
Residence time in the barrel is another critical factor that can contribute to polymer degradation. Extended and high-heat residence times can lead to a mass of degradation issues. At Luxus, we strongly advise against prolonged exposure to high heat unless we are informed and can adjust our material formulations accordingly. Transparent communication about your manufacturing process allows us to optimize our compounds for your specific conditions, ensuring the longevity and quality of the final product. 

Knowledge is Power, Collaboration is Key 
In the world of recycled plastic compounding, knowledge is power, and collaboration is key. We invite manufacturers and mould tool designers to open a dialogue with us. By sharing your requirements, challenges, and specifications, we can work together to develop solutions that not only meet but exceed your expectations. The more we know, the more we can help you achieve your sustainability goals without compromising on quality or performance.  
From Vision to Action: Leading the way in Sustainable Plastic Innovation

Our transformative journey began in March 2016, when we embarked on our partnership with Operation Clean Sweep (OCS). Through OCS, we have made significant strides in reducing plastic pellet loss and protecting our delicate ecosystems.  
Pioneering a Sustainable Journey 
Our partnership with OCS represents a strategic shift towards proactive sustainability. In line with the European Commission's efforts to combat microplastic pollution, this partnership is built on the belief that effective pellet containment requires a collective effort involving primary producers, converters, distributors, logistics partners, and recyclers. This collaborative approach lies at the heart of our commitment to making a difference in the battle against plastic pollution. 

Setting New Standards with OCS 
As a business, we have wholeheartedly embraced the Operation Clean Sweep Standard by implementing a comprehensive set of on-site measures meticulously designed to prevent and address pellet spills. This approach not only ensures compliance but also propels us beyond industry norms, solidifying our dedication to creating a cleaner and safer environment. 

Committing to OCS Principles 
Our commitment to OCS goes beyond mere corporate strategy—it is an ethos we share. By taking the OCS Member Pledge, we pledge to uphold the fundamental principles of the OCS Program. We extend this call to action to all our employees, recognising that everyone plays a pivotal role in achieving a collective goal of minimising pellet loss. 

A Global Movement 
Operation Clean Sweep goes beyond industry boundaries—it is a global movement that tackles the critical issue of plastic resin loss. 
We're proud to collaborate with OCS, joining more than 200 likeminded organisations in sharing success stories and best practices to reduce global plastic resin loss. 

Join Us in Pioneering Change 
Understanding the profound impact of preventing plastic resin loss on the well-being of our planet, we want to invite other businesses to join us in the Operation Clean Sweep mission. Be part of the movement towards zero pellet loss and contribute to a cleaner, healthier environment. Together, let's shape the future of sustainable plastics. 
Crafting Sustainability: Tips for a Circular Economy

As we kick off the New Year, let's dive into the world of sustainable recycling and explore how we can all contribute to a circular economy in 2024. 
  1. Sort with Purpose: Begin your recycling journey by sorting materials with precision. Each piece plays a vital role in creating a cleaner, more efficient recycling process. 
  2. Maintain the cleanliness of recyclables: Thoroughly clean items, especially PP, PE, ABS, and PC products. This ensures that the recycled polymers are ready for a new life.
  3. Stay informed: Familiarise yourself with local recycling guidelines. Knowing what can be recycled in your community maximizes your positive impact. 
  4. Set Sustainable Goals: Make sustainability a core objective for your 2024 projects. Aiming for greener practices creates a positive impact on the environment.
  5. Collaborate for Success: Consider partnerships that align with sustainable practices. Collaborating with organisations that champion recycled polymers can easily integrate eco-friendly solutions. 
  6. Innovate Responsibly: Stay ahead by embracing innovations in recycled polymer technology. Equip yourself with the latest in sustainable manufacturing and lead the way in your industry. 
  7. Reduce and Reuse: Incorporate a mindset of reducing waste and reusing materials whenever possible. By minimising consumption and extending the lifespan of products, we can further contribute to the circular economy. 
  8. Educate Others: Share your knowledge and educate others about the benefits of sustainable recycling and the importance of the circular economy. Encourage friends, family, and colleagues to join the movement and make small changes in their own lives. 
  9. Support Local Initiatives: Get involved in local recycling and sustainability initiatives. Support organisations, businesses, and projects that are working towards creating a more sustainable future in your community. 
  10. Spread Awareness Online: Utilize social media platforms and other online channels to spread awareness about sustainable recycling practices and the circular economy. Share success stories, informative articles, and practical tips to inspire and engage a wider audience.  
As we sail through the currents of 2024, let's collectively steer toward a greener future. Embrace sustainable practices, explore the potential of recycled polymers, and make 2024 the year where every project contributes to a circular economy. 

Meet the Team
Muna Abu-Jaber
Payroll Officer

Charis Algar
HR Administrator

Phil Ashman
Team Leader - Engineering

Peter Atterby
Managing Director

Natalie Blanchard
HR Manager

Adrian Brown
Scheduling Co-ordinator

Chris Burwell
IT Manager

Brad Carter
Sales Coordinator

Victor Casal
Shift Leader - Compounding

Lee Damms
Shift Leader Recycling

Luke Daniel
Logistics Administrator

Rachel Deacons
Purchasing Assistant Non Plastic

Brendan Devlin
Operations Director

Pat Foxon
Accounts Administrator

Alice Higgs
Logistics Administrator

Jamie Hipgrave
Laboratory Co-Ordinator

Maciej Jesionowski
Shift Leader - Compounding

Steve Jones
Finance Director

Chris Kemplay
Stock Management Co-Ordinator

Peter Laking
Maintainence/Engineering Manager

David Lilley
Engineering Manager

Daniel Malin
Shift Leader Recycling

Daniel Marsh
Purchasing Lead

Dane McWilliams
Sales Account Manager

Geoff Mountain
Process Manager

Malcolm Odlin
Purchasing Manager

Kevin Paine
Shift Leader - Compounding

Moira Pryor
Recycling Business Process Manager

Mike Selfridge
Weekend Laboratory Manager

David Stilgoe-McCombe
Health, Safety & Enviro. Manager

Chris Stabler-Coxon
Purchasing Ledger Clerk

James Shaw
Shift Leader - Recycling

Graham Stephenson
Development Technician

Natalie Stones
Project Technical Lead

Simon Thompson
Quality Manager

Shaun Watts
Sales Ledger Clerk

Gemma Webster
Factory Manager – Compounding

Nikki Wigham
Senior Sales Account Manager

Mark Wrisdale
Logistics Manager


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