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What is Plastic Extrusion?
Plastic extrusion is a continuous manufacturing process where melted plastic is pushed through a custom die to create a consistent profile shape. Once cooled and cut, these profiles can be used in countless ways — from construction trims and furniture edging to lighting components, seals and tubing.
It’s an incredibly efficient method, ideal for high-volume or repeatable parts. But the true value of plastic extrusion comes from the way it’s managed — and that’s where BWC brings clarity, flexibility, and control.
End-to-End Plastic Extrusion Service
At BWC Profiles, we don’t just extrude plastic — we manage the whole process under one roof. That means fewer suppliers, fewer headaches, and better outcomes for your business.
Design & Development
Every great profile starts with a great idea.
Our design support team helps you refine your concept for manufacturability, strength, and cost-efficiency. We’ll look at factors such as wall thickness, material selection, and functional requirements to ensure your profile performs exactly as it should.
Prototyping & Sampling
Before committing to full production, we can produce rapid 3D-printed prototypes or short extrusion runs. This lets you test fit, function, and appearance before investing in tooling or large-scale manufacture — saving both time and money.
Precision Extrusion & Co-Extrusion
Our extrusion facility in the UK houses multiple lines capable of producing both rigid and flexible profiles, as well as co-extruded parts combining different materials or colours. Whether your design needs strength, flexibility, or aesthetic appeal, we can tailor the process to your exact needs.
Finishing & Fabrication
Once extruded, we can cut, drill, notch, mitre, tap, or machine your profiles in-house. We also offer custom packaging and finishing, meaning you receive parts that are installation-ready the moment they arrive.
Stockholding & Distribution
We know many customers don’t have the space — or the desire — to hold large quantities of stock. That’s why we provide secure warehousing, just-in-time call-off, and nationwide delivery from our 65,000 sq ft facility. You’ll get consistent supply, reduced lead times, and simplified logistics.
Why Work With Us - The BWC Difference
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Scale & capability in the UK: We operate a 65,000 sq ft facility equipped for serious production and finishing
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Flexible approach: Whether you need a standard profile modified or a completely bespoke design with co-extrusion, complex tooling or short run, we can accommodate
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Cost control & simplification: By bringing design, manufacture, finishing, stock-holding and logistics under one roof, we help simplify vendor management and reduce hidden costs (e.g., transport between subcontractors, storage, mismatched tolerances)
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Expert hands: With decades of combined experience in extrusion and die-making, we’re able to spot issues early and optimise your design for manufacturability
Who We Help - Case Scenarios
Our plastic extrusion service supports a wide range of industries and applications: construction and building trims, horticulture, furniture & office interiors, automotive and rail components, and more.
Here are a few use-cases:
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A furniture manufacturer needing a custom plastic profile for desk edging that integrates clips, channels and lighting.
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A horticulture supplier launching a new irrigation tube with internal ribs and flexible joints.
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A building-components firm redesigning door threshold profiles to reduce installation time and logistics hassle.
Next Steps If You're Considering Extrusion
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Gather your concept drawings or sketches (CAD preferred if available).
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Consider the key functions and conditions the profile must meet: environmental exposure, mechanical loads, aesthetic finish, length of runs, volumetric requirements.
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Reach out to us to discuss tooling, run-lengths, finishing options, delivery cadence and stock-holding strategy.
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Let us provide a clear proposal including tooling, unit cost, logistics, storage and delivery — so you have full visibility before you commit.
Final Thoughts
With the right partner, plastic extrusion can be far more straightforward and strategic than it’s often perceived. Rather than being a commodity item, it becomes a value-added component of your supply chain — one that enhances your product, reduces fuss, and delivers on time.
At BWC Profiles we’ve structured our service around exactly that: bringing clarity, capability and accountability to extrusion. If you’re looking to simplify your supply chain and get your plastic profiles right first time, we’d love to talk.
