Case Study - Melba Swintex

Driving Automation and Operational Transformation at Melba Swintex through Innovate UK Business Growth Support

Melba Swintex is a leading UK manufacturer of traffic management and safety products, operating globally and recognised with a Queen’s Award for Enterprise.

Since 2024, Melba Swintex has worked closely with Innovate UK Business Growth to accelerate the adoption of robotics, digitalisation, and innovation-driven productivity improvements.

Melba Swintex faced several interconnected challenges as it sought to modernise its operations. The business required new robotic machinery to increase output capacity, reduce reliance on manual processes, and futureproof the factory, including the need for advanced robotic injection moulding capability and new-generation blow moulding systems.

Across manufacturing and warehouse operations, opportunities existed to automate manual workflows, reduce inefficiency, and integrate digital tools.

In parallel, a series of new product concepts, including innovations with embedded electronics and smart features, required structured IP support, technical engineering insight, and access to wider innovation resources.

Innovate UK Business Growth delivered a multi strand programme of support, coordinating expertise across robotics, digitalisation, manufacturing, and IP.

The collaboration included:

• Support to confirm the purchase and installation of a £780,000 Tederic robotic injection moulder and plans to further invest in a German robotic blow-moulding system.
• Ongoing tracking and validation of automation projects to ensure alignment with Melba’s long-term automation strategy.
• Technical collaboration with AMRC North West to explore life cycle analysis, carbon footprint modelling, solar and digital transformation options, and matched funding opportunities, providing actionable engineering insights and data driven recommendations for automation, sustainability, and digital transformation.
• Referral and engagement with NERIC to explore warehouse robotics, automated material handling, and potential robotics deployment at the new Mayfield Chicks facility, establishing a clear pathway for warehouse automation, growth, and improved future operational efficiency.
• Support through Innovate UK innovation grant mechanisms, enabling an energy monitoring project to identify opportunities to reduce power consumption, increase efficiency, and deploy smart factory technologies.
• Guidance on new product development and IP strategy, including patentability assessment, competitor IP review, patent drafting strategy, and grant and funding eligibility.
• Early engagement with Made Smarter, including an initial diagnostic workshop and follow-up feedback session, helping the company identify practical opportunities to strengthen its digital strategy and develop a clear roadmap for future transformation projects. Melba Swintex has also registered for Made Smarter leadership courses to help develop its internal capability.

This structured support created a clear pathway for redesigning processes, validating automation benefits, developing new products, and preparing Melba Swintex for further R&D and investment.

The installation and commissioning of a £780,000 robotic injection moulder increased production capability and reduced manual handling requirements, with a forthcoming €1.95 million robotic blow moulder expected to expand automation across additional product lines.

Paul Harrison, Finance Director at Melba Swintex, said: "Innovate UK Business Growth has helped us accelerate our move into advanced automation and modern manufacturing. From robotics to IP support, AMRC collaboration and digital adoption, the support has been invaluable in helping us take major steps forward as a business."