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The Process Behind Our Classic Products

We are often asked how our products are made and its more interesting than you may think! Todays blog goes behind the scenes to reveal the process we use to create the growing list of Classic favourites.

Plastic can be formed by several different processes, all with their own benefits and drawbacks. You may have heard of injection moulding, blow moulding and vac forming to name a few. We are Rotational Moulders.

Rotational moulding uses the unique method of slowly rotating a metal tool either over a direct heat source or in a large oven. From our original mounting blocks to the new and exciting Stackaletti, each of our products starts life as powdered plastic polymer (polyethlene). The slow rotating action, combined with the heat allows the polymer to melt and coat the inside of the tool, reaching all the corners and edges (imagine a chocolate easter egg being formed in a mould). We set a timer, just like you would when baking a cake, and allow the ‘cook cycle’ to complete. Each product has a different cook time. A large product like our 4 step mounting block will cook for 45 minutes whereas a small one like a treat toy will cook for just 6 minutes. When the cook cycle is complete, we allow the product to slowly cool using large fans – too fast and it will shrink so it’s a delicate operation! Finally, we can unbolt the tool and gently remove a perfectly formed product.

Due to the nature of rotomoulding, our products are extremely robust. The buildup of plastic in the corners of products as it rotates reduces weak points ensures an exceptionally strong structure – perfect to withstand a hoof or two!

Our rotomoulding experience spans nearly 50 years. When we first ventured into the equestrian market it was clear that our process had many benefits, namely durability, manoeuvrability, and vibrancy – something that was desperately needed in a stagnant world of rotting wooden jump wings and heavy metal stable fittings!

We pride ourselves on solid, heavy-duty products that are built to stand the test of time and are likely to out live us and most certainly outperform their traditional counterparts!
Don’t forget, if you’d like to learn more about specific products, you can now use the FAQ tab on our product listings. There you’ll be able to find further details on size, build and colorways. For even greater detail, or questions with regard to becoming a stockist, please email us today at [email protected] or call the trade hotline on 0161 765 2010.

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