Bringing Weldbrush production back to the UK

• Bring production of the Weldbrush to the UK, keeping delays to set up production to a minimum. 
• Choose the most cost effective and efficient solution for setting up manufacturing in the UK. 
• Create a setup that offers flexible order sizes and colour options.

What we did

The strategy began with several planning meetings across November and December 2024. This helped both teams understand what was feasible and what the tool may require. 

After careful consideration, Bowles and Walker suggested shipping the existing tool from Australia. This would not only reduce SFS’ investment, but also reduce the time it would take to set up manufacturing in the UK. By using the existing tool, there would also be less risk of producing parts that had discrepancies compared to the original.They made it clear that reworking the tool might involve extra time and work on arrival, but that the long-term savings would be worth it. 

Once the tool landed in the UK in mid February, Bowles and Walker assessed its condition and prepared a full feasibility report. This included three repair options ranging from basic fixes to a full redesign using steel components. Together with SFS, they chose a mid-level option that offered a good balance between cost and durability. The team then adapted their production setup to work with the tool’s unique design.

Results:

Bowles and Walker delivered strong results in a short timeframe. They helped SFS successfully move production to the UK, restore a worn tool, and cut production costs significantly. 

SFS had been paying around £11 per unit in Australia, with a minimum order of 500 sets and extra charges for overseas delivery. Bowles and Walker offered more than 50% savings per set on orders of 2000 or more, and included free UK shipping. They also provided flexibility for smaller batch sizes from just 250 sets upwards.This gave SFS more control over cash flow, inventory, and lead times. 

The repair and upgrade work done to the mould has made it suitable for UK production for another 10-15 years. While the tool still requires careful handling, the improvements have made it stable and reliable for current production needs. 

SFS now benefits from faster turnaround, improved communication, and greater flexibility. They can order different colours, run smaller batches, and make decisions with more confidence. The environmental impact of production has also improved, with local manufacturing cutting shipping and emissions. 

The partnership has already led to new opportunities, with SFS now exploring further production with Bowles and Walker. This project shows how smart, honest, and practical thinking can turn challenges into progress.

“We would like to extend our sincere thanks to Bowles and Walker for their outstanding support in the development of our new Weldbrush machine shells. Their team has gone above and beyond in helping us source the right material, ensuring not only durability but also compatibility with our specific application requirements.

The colour matching process was handled with impressive attention to detail, and we greatly appreciated the numerous samples provided throughout development. This collaborative approach gave us confidence at every stage and ultimately helped us achieve the high-quality shells we were aiming for.

It’s been a pleasure working with such a responsive and professional partner. We look forward to continuing this relationship in future projects.” - Drewe Briston, Managing Director of Stainless Finishing Solutions