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Six employees from across the Bri-Stor Group companies Alpha Manufacturing and Bri-Stor Systems took part in no-shave November for men’s health charity Movember.
The team which included, Adam Deakin, Nick Thomlinson, Andy Gear, Louis Spalding, Corey Hammond and Dan Gill, grew their moustaches throughout November whilst raising money for a great cause.
The team were part of a total 220,000 men across the world who took part in this year’s fundraising, and managed to raise a final total of £960 for the Movember charity which has funded over 1,250 men’s health projects globally.
The money raised will go towards funding more than 1,250 men’s health projects in mental health and suicide prevention, prostate cancer and testicular cancer.
Well done team, we’re so proud of your efforts and loved seeing your tash’s!
Alpha has expanded its machining, routing and cutting capabilities for woods and plastics with the investment of the new AXYZ Infinite 6014 ATC CNC Router. This new router follows the company’s investment in the Trident 6010 CNC Router in October 2020.
The Trident helped to support existing production of commercial vehicle floors and van lining, for sister company Bri-Stor Systems. Due to the demand for this service and new design possibilities opening up, the new Infinite CNC Router was purchased to support the production of phenolic ply wood and plastics for a number of sectors and industries.
The new Infinite router allows for quicker change over times between jobs boasting three separate spindle heads with integrated pressure feet. The addition of an automatic tool changer further reduces tool changer over times with a choice of 14 tool stations. The increased bed size (over the Trident) means the machine can cut larger sheets of materials, providing more opportunities for larger components.
Having both of the CNC Router machines in place by the end of 2021 continues our 5-year investment plan that see’s the company dedicate
£4million to new machinery, as it heads towards it’s Industry 4.0 smart factory goals. Previous investments have seen the factory fitted with the longest STOPA Storage System in the UK, the Salvagnini P4 Lean panel bender and the Trumpf TruBend Cell.
As a sheet metal manufacturer, expanding capabilities to offer a further range of material solutions, and bringing all production in-house, gives Alpha the unique opportunity to be a complete one-stop-shop for our customers. By enhancing its offering through onboarding of these two routers, Alpha continues to live up to its reputation as the most technically advanced sheet-metal manufacturer in the UK.
Neal Lafford has been promoted to the role of Operations Director at Alpha Manufacturing, after joining the business 10 years ago as Business Improvement Manager.
After starting with Alpha Manufacturing in 2012 Neal has been instrumental in helping the business expand its capabilities, in fact it’s Neal’s process improvement expertise that was the catalyst for his promotion to Operations Manager in 2018. In this role, Neal oversaw all areas of production quality and engineering and his many and continued successes have led him to this new directorship.
As Operations Director, Neal will work closely with Commercial Director Robin Eley, and Managing Director Paul Clews to continue to bring operational excellence to Alpha and to bring the business closer to its industry 4.0 goals.
Speaking about Neal’s promotion, Paul Clews said: “This move to directorship is well deserved and recognises Neal’s dedication in his role as Operations Manager.
“Neal is someone who in the past 10 years, has worked tirelessly to expand our capabilities, improve processes and used his expertise in lean manufacturing and process improvement to oversee the implementation of key machinery as well as lead a large, expert team.
“In his new role, I look forward to working with Neal on strategy creation and implementation and our industry 4.0 objectives. I have no doubt that Neal will achieve great things in the role and continue to take the company from strength to strength as we continue to grow, with the opening of our new Chemical Technologies development opening next year.”
Neal said: “My time at Alpha has been full of career defining moments, and after starting almost 10 years ago as Business Improvement Manager, I have learnt so much and feel I have grown with the business. I still get a buzz every time we implement a new process or expand our capabilities with new machinery, and I am proud of my contribution to Alpha’s continued success. I look forward to developing new strategies that will further enhance our reputation as a world-class manufacturer.”
The business has won four awards at two events recognising local business success.
Staffordshire based sheet metal manufacturer Alpha Manufacturing, part of the Bri-Stor Group, has become a multi award-winner after scooping four accolades at local business awards.
The business, which offers full in-house design and fabrication services to the UK and European market, was named Manufacturer of the Year 2021 by award sponsor The Greenbank Group at the East Staffordshire and South Derbyshire Business Awards on 11th November. And just one week later was named Manufacturer of the Year 2021 by award sponsor Michelin Tyres, at the Staffordshire Chamber of Commerce Business Awards.
Both sponsors spoke about the innovation displayed by Alpha during the pandemic, where the business geared up its operation to support the hospitality and leisure industry and NHS covid testing centres as the UK re-opened after the first UK lockdown, with the manufacture of hand sanitiser units and protective screens.
Not only did the business take home these awards, but Alpha’s Production Engineer and former Higher Apprentice Gemma Smith also took
home the Young Employee of the Year award at both events, for her work raising awareness of Apprenticeships and women in engineering, as well as her quick progression through the business while committed to her degree and charity work.
On the recent success, Alpha Manufacturing Managing Director, Paul Clews said: “We’re still on such a high after winning these awards. These awards have come at such an exciting time for our business as we experience significant growth with the opening of two new sites, including our Beacon Park, Stafford facility, Chemical Technologies in collaboration with global company INEOS Electrochemical Solutions.
“But it’s the team that are truly award-winning at Alpha, we’re so lucky to have a business with such dedicated and committed people who never fail to go the extra mile. I am proud to be part of this incredible team, there are so many great opportunities ahead of us, it’s a great time to be Team Alpha.
“A huge well done to Gemma too who bagged another thoroughly deserved Young Employee of the Year award, it’s been a privilege to see Gemma achieve so much in the past five years at Alpha, she is testament to our Higher Apprenticeship programme, and I know she has such a bright future ahead.”
Gemma Smith said: “Winning one award was a shock, never mind two! First of all, massive thank you to Alpha Manufacturing for everything they have done for me in pursuit of my dream engineering career. I have benefited greatly from being given opportunities often outside my comfort zone, but those opportunities have served me well.
“Finally, a huge thank you to the judges from East Staffordshire & South Derbyshire Business Awards and Stafford Chamber of Commerce for believing in me and choosing me for this award. You don’t know how much it means to me to be recognized for my achievements and I feel proud to be recognized amongst a group of equally talented finalists and flying the flag for Apprenticeships, they are the future.”
TIG Welder Sean Atkinson originally joined Alpha Manufacturing on a temporary contract but after showcasing his excellent skills and abilities, Sean quickly secured a permanent position and has been a valued member of the team for over a year.
Sean originally began his career as a plumber, but when looking for a change in career path, he decided to pursue his passion for TIG Welding, having previously achieved welding qualifications at college.
Sean tells us about what it’s like to be a TIG Welder at Alpha: “I work in the stainless steel department here at Alpha, mainly welding specialised parts for the food manufacturing industry.
“My day usually starts with my pre-checks, inspecting my welding set-up and ensuring that my materials and tools are in good working order. After this, I check the job list, looking specifically at the dates and priorities of each, in order to organise my work for the day.
“Before I start a job, I will need to thoroughly check the engineering drawings for the specifications. This can sometimes lead me to working closely with team members from other departments such as CNC folding or laser, to liaise on the fabrication of parts.
“I TIG weld a variety of parts throughout my day, sometimes using specialist techniques such as more complex purging to provide the upmost quality and uphold customer specifications. I then work with our linishing team on parts that need their services, and then quality inspect each part before it is delivered to our customers.
“What I really like about my job is the variety of work that I do, each part can be different which means I am constantly evolving my skills and learning. I am especially excited about the next phase of my role that comes with the opening of the new Alpha Manufacturing Chemical Technologies facility. Here, there will be specialised welding of exotic metals and my role will see me helping to co-ordinate and set up operating processes for the new factory.
“It feels fantastic to have been given the opportunity to be a part of this exciting development for Alpha, and that our TIG welding team will be growing with a new team based at the Chemical Technologies site next year. I look forward to my future here at Alpha, I hope to keep progressing my skills and knowledge and to eventually manage a team.”
Production Engineer Gemma Smith also awarded Young Employee of the Year
Staffordshire sheet metal manufacturing company Alpha Manufacturing is celebrating its achievements after being named ‘Manufacturer of the Year 2021’ at the East Staffordshire and South Derbyshire Business Awards. Commended at an awards ceremony held on 11th November at the Pirelli Stadium in Burton, the fabrication company was recognised for its innovation during the pandemic, where the business quickly geared up its operations to support production of Covid-19 safety products, including hand sanitiser stations and protection screens used in NHS testing centres across the UK.
Alpha Manufacturing Production Engineer and former Higher Apprentice, Gemma Smith was also recognised at the awards evening, taking home the prestigious Young Employee of the Year award. The judges commended Gemma for her many achievements which include inspiring the next generation of engineers, raising awareness of women in engineering and apprenticeship routes, as well as her charity work which includes climbing Mount Kilimanjaro to raise money for an African children’s charity and taking on a Unicycle challenge to raise funds for Alpha Manufacturing’s charity partner and local hospice Katherine House, all whilst completing her degree.
Not only did the company take away these two awards, but it was also recognised as Highly Commended in the Best Use of Innovation or Technology category for its work towards Industry 4.0 Smart Factory goals, including implementing new technology and machinery such as the STOPA storage system which is the longest in the UK.
Talking about the win, Alpha Manufacturing Managing Director Paul Clews, said: “This award is a testament to the hard work and dedication of our team. It’s the people that make a business and without them, we wouldn’t be winning this award.
“During the pandemic, we kept production moving on essential items and within three months had the whole workforce back working within regulations, namely on Covid-19 safety products. To think that the products made here in our Hixon facility have helped to keep the UK safe as the country opened up again, and to continue to see these products helping to keep the country moving, makes me incredibly proud.
“A massive well done to Gemma too, who was our first ever Higher Apprentice here at Alpha, and who has continually pushed herself to be an exceptional role model to other young engineers. She always goes above and beyond in her role and is a real asset to our team.”
On winning the Young Employee of the Year award, Gemma Smith said: “I was totally speechless when they announced my name – I just couldn’t believe it. All of the other finalists were so worthy of winning, and so I was glad that I was able to share the stage with them.
“I just hope with this award I can show other young people, especially young women, what can be achieved through apprenticeship routes and to inspire people to go into engineering. I’m so lucky to have had the support of Alpha Manufacturing who not only funded my education but helped me every step of the way.”
The Alpha Manufacturing production team has grown again with the appointment of Nick, who previously worked at JCB for 11 years, most recently as a Manufacturing Group Leader managing a large team in the load-all division.
Nick’s new role involves him overseeing all aspects of manufacturing operations and production processes, working with Operations Manager Neal Lafford, to ensure smooth production of parts and operational functions.
Nick’s appointment comes at a busy time for Alpha, as the company continues to grow its order book, expand its processes with new technology investments, and with the opening of two new sites, including the latest development in build, Alpha Manufacturing Chemical Technologies.
About his new role, Nick said: “I’m someone who continually wants to grow my skills and learn, so I’m really looking forward to getting to know this new business. Having worked in the manufacturing industry for many years, one thing I have never worked on solely is sheet metal, so it’s the perfect challenge for me to get to know these new processes and machinery.
“One of the things I am already enjoying about Alpha is the variety of our customer base and the scope of innovative projects the company is working on. There’s a real family feel about his company that is unique, and I’m already proud to be a part of it.”
Having the capability to offer customers a complete range of solutions for welding and fabrication jobs is just one of Alpha Manufacturing’s unique advantages. In this article, production engineer Gemma Smith, explores the benefits of manual and robot welding and explains how Alpha customers benefit from this market-leading service.
“There are so many processes involved in the fabrication of just one product, but the beauty of an Alpha manufactured component is that every area of our production uses the best available technology for that particular process. There’s no question, certain methods have their unique advantages and welding is no different – not only from a process and application capability but from a value engineering process too.
“The manual welding process has great flexibility and can be involved in a wide range of applications. One of the first differences between manual and robot welding is that manual welders are able to work with a variety of different thicknesses and a mix of products using their own skill and knowledge base, rather than requiring a programmer to set up before each use.
This method also means that high complexity can be achieved as manual welders can navigate hard to reach weld sites. One of the unique benefits of manual welding is that it’s the perfect solution for low quantity runs and prototyping, enabling the welder to use their skills and expertise.
“But that’s only half of the welding story. At Alpha Manufacturing, arguably we have the most exhaustive robotic welding capability in the
UK including the Yaskawa Robotic Welding Machine. Featuring ‘cold metal transfer technology’, Alpha customers have come to rely on world-class weld standards. While manual welding has many advantages, robotic welding delivers consistently high quality output with a high repeatability rate, as the robot follows the exact same programme.
“There’s no question, for Alpha customers having the in-house capability to deliver a broad spectrum of weld techniques is just one of the Alpha Manufacturing differences. Whether a component is welded in one of our weld bays by one of our expert weld team or a component is passed through our automated welding machinery, every component manufactured in our Staffordshire production facility achieves the same world-class standard. That’s our commitment to every Alpha Manufacturing customer. It’s what we’re famous for.”
Find out more about our welding services or read more from Gemma Smith.
In August, Alpha Manufacturing held its first ever Recruitment Open Day. With up to 30 positions available in a range of skilled and semi-skilled roles, candidates were offered the chance to interview for their preferred role on the day.
In attendance at the Open Day was Libby Mellor, a former Mechanical Engineering Apprentice who found her passion in the Quality Department at Perkins during her apprenticeship and had progressed to the role of Quality Inspector in her fourth year at the company.
Libby attended the Open Day with the aim of finding out more about Alpha Manufacturing and the roles available within the Quality Department. Speaking about her new role, Libby said: “I think it’s fascinating to see how other companies work, whether you’re looking for a job or not, and so it was great being able to take a look around the factory at Alpha and see all the facilities first hand.
“I had heard a lot about the progression opportunities available at Alpha and how they support people through education and training, and as I was ready to take my next steps in my career, Alpha seemed like the perfect place.
“At the Open Day, I spoke with the management team about looking for my next challenge within the industry, and it wasn’t long afterwards that I was offered the position of Trainee Quality Engineer. I was so thrilled to have been offered the perfect next step that I was looking for, at a company that I had been so impressed by.
“Having worked here a couple of weeks now, I’m still learning the ropes but am so excited to get stuck into my role. The main thing I’m looking forward to is planning and investigation, where I will be evaluating potential quality risks before they arise to contribute to the company’s high-quality standards.
“My overall hope for the future is to keep learning and progressing in my career, hopefully working my way from Trainee to Quality Engineer and eventually I would like to manage a team and go into the Quality Management side of things.
“At the moment, I’m really enjoying getting to know all of the processes and the team here, who have all been so friendly and welcoming! My advice to anyone wanting to take their next steps in their career is to go for it. By taking a chance you could find the perfect job for you like I have at Alpha.”
We wish Libby all the success in her new role and it’s great to have her as a part of Team Alpha.
Find out more about our Quality Department, or meet Quality Manager Ben Austin and Quality Inspector Peter Ricketts.
I’m Charlotte Allen, I am a first-year Level 3 Engineering Technician Apprentice with Alpha Manufacturing. I am your typical 17-year-old girl that likes fashion and shopping. I have just bought my first car and I have recently started to learn how to play golf.
Growing up, I was always fascinated with my dad’s job as an engineer. He started as an engineering apprentice when he left school and has since spent the last thirty-five years working in the surface finishing industry as a Project Manager. Hearing about my dad’s job is where my passion for engineering came from.
Throughout school, I felt as though sixth form and college were my only options after completing year 11. Since like most fourteen-year-olds, I had no idea what I wanted to do or what GCSEs to take, I did what I enjoyed the most and later left school having passed: dance, drama, health & social care and geography along with math’s, English and science. If you were to tell me at fourteen that almost 3 years later, I would be working in steel toe cap boots I probably would have laughed at you!
Knowing A-level couldn’t be the only choice for my future, my dad and I found Bri-Stor Group Apprenticeship Scheme through Made in the Midlands and it was like all my wishes had been listened too, finally I had found somewhere that I could gain experience, recognised qualifications and have the bonus of earning myself a wage slip at the end of the month.
Coming straight from school to a work environment definitely takes some getting used too.
Our first day consisted of getting to grips with JCB Academy, where the first year of our course is predominantly taught, and learning what day to day life would be like there. At first, if somebody had asked me if I could use a file, I would have shown them my nails. From getting the coach to learning how to take apart an air compressor, using hand tools to then operating a milling machine, my first month has been a whirlwind to say the least.
On our second day we went on a trip to Alton Castle where we carried out lots of activity to become closer as a group and push ourselves outside of our comfort zones.
The rest of my days are filled with learning about how to work all the different machines in the workshops and experimenting with CAD software.
Whilst being on site at Alpha we have been learning about all our health and safety responsibilities whilst in the workplace and starting our soapbox ideas in preparation for next march. As a small group we have settled on doing a Star Wars themed soapbox and will be starting the process of replicating it in the weeks to come.
With everything we have learnt over the month I have partially enjoyed the business side of the course, for example, business improvement and organised efficiency where we are looking at different types of production and currently creating our own standard operating procedures. My SOP covers the manufacturing of a golf club, so maybe you’ll see me playing in the golf society with my very own made golf club. It is really interesting to see what goes into the manufacturing process of everyday items that we all recognise.
Moving forward in my career I would like to branch out into the business side of things, such as Technical Sales or Marketing but it is important to me first before moving into that area of the business to know as much about the products we sell as possible. I am so exciting about the future of Alpha Manufacturing and would love to get the opportunity to work at the new Chemical Technologies site in Stafford opening next year!
Another one of my passions since moving into this industry is raising the profile of women in engineering and possibly going into schools to talk to pupils about all they can gain from an apprenticeship after leaving school. It is important to me that young girls can understand and visualise a modern engineering environment like Alpha, and see it as a space where you can achieve anything and go into so many exciting areas from aerospace to automotive and manufacturing. I believe that the different routes into industry should be projected more to children before leaving school who don’t think the traditional education only route is for them.
In the end, I hope to have a long and successful career in this industry and maybe even one day be like famous engineer Thomas Telford, a Managing Director like Paul Clews or even our very own Alpha Manufacturing welder Chloe Sales! Only time will tell, but what I do know is I will have full support from Alpha every step of the way in my future as an engineer. Watch this space…
Shortlisted as a finalist in both the Manufacturer of the Year and Innovation & Technology category, with an employee also shortlisted as a finalist for the Young Employee of the Year Award.
Staffordshire sheet metal manufacturing company, Alpha Manufacturing has been announced as a finalist in three award categories at the prestigious East Staffordshire and South Derbyshire Business Awards.
The company is proud to have been selected as a finalist for the Manufacturer of the Year and Innovation & Technology Awards, with Production Engineer Gemma Smith also shortlisted as a finalist for the Young Employee of the Year Award.
The award comes at an exciting time for the business, which has seen significant growth in the last 18 months despite the challenges brought about by the pandemic. Since the start of this year, Alpha Manufacturing has seen a surge in demand for quality UK sheet metal manufacturing, resulting in the opening of two new divisions; Alpha Integrated Technologies and the most recent being Alpha Manufacturing Chemical Technologies, a 35,000sq ft purpose-built manufacturing facility in Beacon Park, Stafford in partnership with global chemical company INEOS Electrochemical Solutions.
The growing company’s production facility is the most technologically advanced in the UK. The recent extension of its STOPA storage system makes it the longest installation of its type in the UK and allows it to offer an unrivalled level of service in terms of efficiency and value. Commenting on the news, Alpha Manufacturing Managing Director, Paul Clews said: “What fantastic news! Being selected as finalists for these awards alongside other fantastic local businesses is a credit to the hard work and dedication of the Alpha Team who have worked tirelessly throughout the last 18 months to not only keep the business running through the pandemic and supply essential COVID safety products to customers across the UK, but to open two new sites since the start of the year, in response to unprecedented demand for our services.
“Our long-standing Apprenticeship Programme continues to produce some incredible young engineers and will continue to drive our business into the future. Gemma is the perfect example of a talented, dedicated and exceptional young individual whose commitment to everything she does makes us proud to have her as a part of our team.”
Production Engineer and former Higher Apprentice Gemma has been selected as a finalist for the Young Employee of the Year Award due to her achievements in her career so far, her commitment to raising awareness of STEM pathways for young women and her charity work. Gemma said: “I’m so happy that Alpha Manufacturing has put me forward for this award – it feels like a dream! Since completing my degree at Derby University through my Higher Apprenticeship at Alpha Manufacturing, I have worked hard to progress my skills and knowledge while also aiming to be a role model to other young women who want to pursue an engineering career. It just shows where hard work can take you!”
As well as being recognised for her performance and skills in her role at Alpha, Gemma has also raised money for local hospice Katherine House through a Unicycle Challenge and even climbed Mount Kilimanjaro for an African Children’s Charity while completing her degree.
The winner for each award will be announced at an Awards Evening at the Pirelli Stadium in Burton-on-Trent, home of Burton Albion FC, on Thursday 11th November.
In August, Alpha Manufacturing held its first ever Recruitment Open Day. With up to 30 positions available in a range of skilled and unskilled roles, candidates were offered the chance to interview for their preferred role on the day.
Offering robust training schemes and professional development opportunities, a Group bonus scheme and competitive salaries, the Open Day was a great success with over 70 potential candidates attending over three time slots throughout the day, and almost all roles filled, with some candidates being offered the job on the day.
Amongst the attendees on the day was Roffy Chitumba, a recent Masters graduate in Advanced Product Design, who was looking to start his career in the engineering industry. Roffy picks up his story from here: “As early as I can remember I have always had a passion for engineering, always wanting to understand how machines and moving parts work, but growing up in Zimbabwe there were not many higher education pathways for me to develop the knowledge and skills required.
“After moving to England to pursue my education, I attended University to study Aeronautical Engineering in Manchester. Once I graduated, I worked in technical support for a consultancy for a while, but I wanted to continue my education in engineering and manufacturing, to give myself the best start to my career in this area, which is why I pursued my Masters degree in Advanced Product Design.
“I found out about the Recruitment Open Day at Alpha Manufacturing through social media, and it came at the perfect time for me, having recently completed my Masters degree. I was so impressed with Alpha’s Apprenticeship Scheme, Higher Apprenticeships and training opportunities it seemed like a company that really invested in its employees.
“At the Open Day, I took a tour around Alpha’s facilities and was fascinated by the scale of the factory and the world-class machinery. It’s exactly the kind of place I had dreamed of working, somewhere I can get stuck in and put my theory knowledge into practical experience, learning every part of the production process. Meeting the wider team, including an interview with Operations Manager, Neal Lafford, was really interesting and after a nervous week waiting to hear news, I was absolutely thrilled to be offered the position of Quality Inspector with the goal of becoming a Production Engineer. My skills, knowledge of CAD design and modelling, made me the perfect fit for this area. I couldn’t believe it when I got the offer. It was a dream come true, to be offered the role I applied for with the scope to progress.
“The first month has been a whirlwind experience. I took part in a two-week induction, working on the factory floor operating machines, welding, polishing and getting some hands-on involvement of the journey in which parts go through in the production line. This week, I am finally in the Quality team and I’m already loving it. Through a combination of the knowledge learnt during my degrees and getting to know the manufacturing methods on my induction, this has helped me to get into the mindset of a Quality Inspector; being able to spot possible areas within the production of a component where issues may occur and working with the Production Engineers to find solutions.
“I already feel a part of something special here at Alpha and am looking forward to doing the best possible job I can do for the company. My advice to anyone who is worried about applying for their dream job, just go for it! Never give up, as there may be the perfect opportunity out there for you, like this one at Alpha is to me. If you’re willing to work hard and get stuck in, then good things will happen. Follow your dreams!”
Are you looking for your dream job? Take a look at our available positions on our careers page.
Find out more about our Quality Team, meet Ben Austin and Peter Ricketts.
For businesses, as with every aspect of day-to-day life, the COVID-19 pandemic brought many unavoidable challenges, the like of which had never been seen before. Yet, there were opportunities scattered amongst the trials, some of which as a business, Alpha Manufacturing was able to adapt and rise to within mere weeks.
As lockdown took force, Alpha Manufacturing kept essential work moving while still enforcing safety regulations by reducing to a skeleton shift on the factory floor, and with office staff working from home to safeguard our employees. As the situation developed, demand for COVID-19 protection products soared and we adapted our manufacturing approach rapidly to meet the surge in demand for our expertise and capability.
Within weeks of the first UK lockdown, the Commercial Team were approached by a retail display company who had an urgent demand for 3500 hand sanitization units for the leisure and hospitality sector. We were able to quickly set up production lines to manufacture and assemble 450 units per day. Since this initial project, Alpha has built a relationship with this customer, collaborating to develop the design of a second-generation sanitizer and combined cleaning unit at a rate of 150 per day. The end-client is a leading UK supermarket with c.7000 stores nationwide.
Another customer win during the UK lockdown was a Staffordshire-based internal partition screen supplier who was struggling to meet the surge in demand for their products. An initial requirement of 1250 COVID screens were produced at a rate of 300 per week and again, the relationship has developed since, with further screens produced by Alpha for various purposes including NHS testing stations.
We maintained a supply to those customers connected to healthcare and when required, quickly implemented robust safe working practices so that we could quickly up-scale operations in line with our customers’ demand. We are an agile business and there is no better illustration of this than our ability to ‘gear-up’ and switch our focus towards supporting new partnerships while maintaining momentum and supply certainty with our existing customers.
A year later, and we are still working hard on multiple orders of the COVID safety products for these customers and new ones, with new orders coming in all the time. Working closely with our customers, we have designed and developed updated versions of the product with our in-house team of innovators.
Commercial Director, Robin Eley heads up the team who are the first point of contact for our customers: “The events of the past year have
allowed us to forge even stronger relationships with new and existing customers, supporting with urgent requests to keep essential services moving, such as hand sanitisers and vehicle partition screens.
“During this time, our team worked tirelessly to design, produce and deliver these critical items for our customers. Throughout the whole process, we worked hand in hand with our customers, making sure the products were to the top quality they could be, even whilst working with the reduced staff and with supply chain issues brought about by the pandemic.
“Now, a year on, after building strong relationships through this difficult period, we are still the trusted partner for our customers. Every day we receive orders for the COVID safety products first produced last year, from new and loyal customers.”
Being the most environmentally efficient business in the sheet metal manufacturing industry is at the core of Alpha Manufacturing’s strategy, leading the industry towards greener and more sustainable practices. Sharing a 35-acre site with sister company Bri-Stor Systems and Atlas Coating and work beginning on the new, 65,000 sq. ft state-of-the-art Alpha Manufacturing Chemical Technologies site in Stafford, Alpha is already exceeding its 5-year targets to reduce energy consumption, waste to landfill and increase recyclable waste.
We spoke with Bri-Stor Group Health, Safety and Environmental Manager Darren Bates, to find out more about how the business has achieved this success.
Tell us more about environmental strategy and why it’s so important.
“The 14001 epitomises how important having a stringent environmental policy in place is to businesses. We know our targets are ambitious, but achievable, and we’re a company ready to make a mark in the manufacturing industry for our sustainability goals.
“Our 5-year environmental strategy consists of three key areas: Reduction of electricity and energy consumption, reduction of general waste produced and therefore waste to landfill, and increase our recycling waste rate. One year in to this plan, we are exceeding our goals through innovative and proactive approaches.
The strategy will allow us to futureproof our business and be the catalyst of change in our industry.”
How have you managed to reduce energy consumption across Alpha?
“As a large site, with 24/7 manufacturing capability, reducing energy consumption has always been a top priority for our company. Recently,
our factory underwent a large project to make a big dent in our average energy consumption, futureproof our business and reach our 5-year targets. By strategically converting all lighting on premises to CEMA LED Lighting, we have reduced our kWh production by nearly half a million. The kWh of energy saved is equivalent to 36,344,455 smartphones charged! This has resulted in us already beating our yearly kWh electricity target by over 13%, which is an annual CO2 saving of 107.76 tonnes, equivalent to 270,822 miles driven by an average passenger vehicle.
“This is not the only energy saving innovation we have planned either. A project is under way to have switched completely to solar power in the next four years. The installation of solar will see our 3,570.5 square meters of our facility installed with 1960 roof-mounted solar panels. This will produce a kWh energy saving of around 733,043 per year, with the eventual aim to be entirely self-sufficient in our energy usage within six years.”
Across the Bri-Stor Group, we were previously producing 200 tonnes of waste per year, how has the plan allowed us to reduce the amount of tonnage wasted and by how much has it reduced this by?
“Having switched to three bailers and one mini-compactor to decrease the amount of waste that goes to landfill, we have now reduced our carbon footprint by 75%.
“As a business, we are now classed as a ‘zero to landfill’ company, working with leading waste management company Veolia, who themselves stopped using landfill around 18months ago, as our waste is now processed into Reuse Derived Fuel (RDF). The RDF process replaces fossil fuels such as coal, gas and oil. Filtration is used to produce as much lower CO2 than regular methods, meaning it is cleaner and less harmful to the environment.”
How significant is recycling to Alpha and how have we increased the amount of waste material we recycle?
“Intrinsically linked with the goal of reducing general waste is the increase in recyclable waste. With an excess in quality materials, making sure these are recycled and not wasted, is key to our strategy.
“The bailers are used to mass recycle our waste materials such as all cardboard and plastic. The implementation of this equipment, along with building a workplace culture around reusing and recycling, has meant that we are on track to beat our ambitious target of 55 tonnes of recycling by the end of 2021.”
In summary, what is the future of the environmental strategy for Alpha?
“These initiatives across the three strategic areas, have meant that in 2021, we are already not only on track to meet our environmental targets but in some areas beating these already, and our hope is that we will have exceeded our ambitious targets by the end of the year. This will also have a big impact on the entire 5-year plan, which we hope will mean we can keep excelling in implementing our environmental strategy and innovations, to be one of the most ‘green manufacturers’ in the industry.”
Having worked for JCB for 15 years, most recently in the Global Major Accounts department as General Manager, Michael Whitfield has joined Alpha to support recent business growth and continue to drive the company forward.
Michael’s new role will see him working with Commercial Director, Robin Eley and Technical Sales Engineer, Corey Hammond, building relationships with new and existing customers and supporting the continuing growth of the business.
Michael’s appointment comes at an exciting time for Alpha, as the company is experiencing unprecedented demand for its services with the opening of two new sites this year; Alpha Integrated Solutions and Alpha Manufacturing Chemical Technologies, a brand new 35,000 sq ft facility in Beacon Park, Stafford in collaboration with global brand INEOS Electrochemical Solutions.
On his new role, Michael said: “As someone who is passionate about the engineering and manufacturing industry, I’ve been following the evolution of Alpha Manufacturing, and the whole Bri-Stor Group for a long time, and have always been impressed. Something that really stands out is the way Alpha values its staff, and has such strong relationships with its customers.
“I have no doubt Alpha has an exciting future ahead as it continues to grow and I look forward to being part of that journey.”
Living locally to Hixon, Michael lives with his wife and two young children. The family are active in the local community and although having young children occupies much of his time, Michael enjoys keeping fit through running and playing football with friends as well as embarking on DIY projects at home.
Welcome to the Alpha Team Michael, and good luck in your new role.
