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.
Scale & capability in the UK: We operate a 65,000 sq ft facility equipped for serious production and finishing
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
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)
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:
A furniture manufacturer needing a custom plastic profile for desk edging that integrates clips, channels and lighting.
A horticulture supplier launching a new irrigation tube with internal ribs and flexible joints.
A building-components firm redesigning door threshold profiles to reduce installation time and logistics hassle.
Gather your concept drawings or sketches (CAD preferred if available).
Consider the key functions and conditions the profile must meet: environmental exposure, mechanical loads, aesthetic finish, length of runs, volumetric requirements.
Reach out to us to discuss tooling, run-lengths, finishing options, delivery cadence and stock-holding strategy.
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.