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Paul Clews, Managing Director of Alpha Manufacturing, explains how blending customer-driven innovation with the latest advances in technology is proving to be a recipe for success.
After a record-breaking year in 2025, when turnover topped £22.5m, Alpha Manufacturing has carried strong momentum into 2026. We also smashed previous targets on the number of parts we designed and manufactured, hitting 1.4 million, up 28% year on year.
The phrase “work smarter, not harder” has a lot of merit. However, as a leader in our field, 2026 has continued to show why we believe in doing both. We are constantly looking to innovate, but also to go the extra mile for our clients.
As we now stand firmly in the second half of 2026, I am delighted to report that Alpha Manufacturing remains on an upward trajectory. Here are some of the highlights from this year so far:
Peer recognition
One of the standout moments of the past six months was being named Engineering Manufacturer of the Year at the Made in the Midlands UK Awards. This is part of a national series of accolades designed to recognise the very best manufacturers from across the UK.
Here’s what the award organisers had to say about us: “The judges were very impressed with this entry, which ticked all the boxes for innovative and sustainable manufacturing. It has strong targets in sustainability, a clear innovation strategy and a commitment to developing the region’s talent and industrial base.”
Alpha Manufacturing was also proud to contribute to wider Group success, as The HEX Group scooped the Business of the Year award at the coveted Staffordshire Chambers Awards. The accolade recognised a period of exceptional growth, investment and innovation across the Group, underpinned by major new and ongoing customer partnerships, continued investment in advanced manufacturing technologies, and an unwavering commitment to skills development, sustainability and long-term business resilience.
Adding genuine value
A key differentiator for Alpha Manufacturing in 2026 has been its growing ability to add genuine value for clients. By combining advanced CNC punch tooling, forming techniques and intelligent programming, Alpha Manufacturing continues to eradicate processes within customer operations. This reduces cost, lead time and environmental impact, while improving repeatability and quality across product lifecycles.
A critical element of this progress is that we combine scale with flexibility. The ability to manufacture millions of parts annually while managing thousands of unique components enables Alpha Manufacturing to support customers at every stage of growth, from prototype to full production. This balance, combined with the reliability of a UK-based supply chain, is strengthening Alpha Manufacturing’s position as a trusted partner rather than simply a supplier.
A clear example of exceeding customer expectations this year is the recent adoption of metrology-grade 3D scanning technology to support increasingly complex fabrication requirements.
Customers in sectors such as energy, infrastructure and data centres require high levels of dimensional accuracy, traceability and confidence in quality. Traditional inspection methods were becoming increasingly time-consuming and limited in the data they could provide. In response, we invested £130,000 in a Creaform MetraSCAN 3D system, typically used in aerospace applications.
This means we can now capture millions of data points per second, delivering inspection accuracy of up to 0.025mm. It has significantly reduced reliance on manual measurement, shortened inspection times and improved repeatability for high-volume work.
For customers, this translates into increased confidence in product quality, faster response to queries and clearer evidence of compliance. We are also developing a digital library of scanning templates, enabling rapid inspection of repeat parts and further improving efficiency.
We are also using AI-enabled condition monitoring to enhance preventative maintenance and uptime. These are just a few examples of how the latest technology is paying dividends for our clients in 2026.
Investing for success
These purchases are part of a broader investment programme that demonstrates how Alpha Manufacturing continues to evolve by embracing new technologies and smarter ways of working and that has already delivered significant advances in automation and productivity. To build on this progress, we have ordered a TRUMPF TruLaser 5030 paired with a LiftMaster Compact, fully integrated with our STOPA storage system. Once installed, it will further support lights-out production, helping us increase capacity while maintaining the high levels of quality and efficiency our customers expect.
Together, these investments are transforming productivity, reducing manual handling, enhancing accuracy and enabling us to operate as a truly 24/7 manufacturing facility. The result is a step-change in capacity and efficiency, enabling Alpha Manufacturing to simultaneously handle both high volume production and complex work.
Importantly, the business has continued to fund this growth through reinvestment rather than debt, ensuring financial resilience and long-term sustainability.
We have also brought more logistics in-house after investing £130,000 in a new 18-tonne Volvo FM Globetrotter truck to further enhance delivery performance and value for our customers, replacing our 7.5-tonne vehicle, which is retiring after years of faithful service. The new truck enables us to maximise load efficiencies and increase the volume of products delivered on each journey. Its sleeper cab also allows us to travel longer distances while maintaining flexibility around driver hours. Following the success of this investment, we have already placed an order for an identical vehicle, alongside two additional 3.5-tonne trucks, further strengthening our fleet and supporting future growth.
With greater payload, increased load height and maximised load space, the new Volvo FM is enabling us to carry more orders per journey. This improves efficiency while cutting emissions and reliance on subcontract hauliers.
This investment is more than a new truck; it is part of a strategic upgrade to our logistics operation and a clear statement of intent for continued growth. With the introduction of paperless operating systems, live vehicle tracking, real time tachograph monitoring, and instant electronic Proof of Delivery, we can now ensure complete visibility and control across every delivery.
Putting people first
Alongside this capital investment, 2026 has also seen Alpha Manufacturing continue to put people first, with a firm focus on developing talent and helping our people reach their full potential.
Through The HEX Group Academy, Alpha Manufacturing has now trained more than 200 apprentices since 2010, with the latest intake of 22 joining last September and continuing their education journey with the company. By tailoring apprentice intakes and training programmes to the evolving needs of the business, we are ensuring we have the skills required to support future growth and technological advancement. Each annual intake has achieved a 100% pass rate while supporting both its own workforce and other regional manufacturing businesses.
Leaner and greener
Sustainability has also remained embedded throughout Alpha Manufacturing’s operations in 2026. As part of The HEX Group, we follow the HEX360 strategy, working collaboratively with customers to support their environmental goals, from reducing embodied carbon through smarter design to efficient production and logistics.
Over 2,000 solar panels now generate enough energy to operate our machinery, while LED lighting has reduced energy consumption by more than 43%, and waste reduction initiatives have cut carbon footprint by 75%. Alpha Manufacturing has also committed to achieving carbon neutrality by 2037.
Looking ahead…
While we are proud of what we have achieved so far in 2026, we are not standing still. The investments we are making in technology, sustainability and our people are all focused on one goal: helping our customers succeed.
The second half of the year promises to be just as exciting, and we remain committed to working smarter and harder to deliver the innovation, quality and service our customers have come to expect from Alpha Manufacturing.
Turning an innovative infrastructure concept into a production-ready system takes more than good design. It takes close collaboration, practical manufacturing expertise and a shared ambition to
make the idea work at scale.
UB Infrastructure partnered with Alpha Manufacturing to transform its panelised building concept into a fully functioning demonstrator unit, proving its potential for consistent manufacture, efficient assembly and wider commercial deployment.
“Our experience of working with Alpha Manufacturing has been extremely positive. Alpha Manufacturing has brought a strong manufacturing mindset, impressive facility capability and a genuine willingness to understand and develop the UBI system with us.”
UB Infrastructure’s panelised building system has been developed to support faster, more consistent delivery of operational buildings across the rail and wider infrastructure sectors.
Through standardised design, off-site manufacture and installation, the system aims to reduce on-site risk, shorten project programmes and improve whole-life maintainability.
Creating the demonstrator unit was a significant milestone. Every component, from aluminium panels, doors, trims, guttering, lighting, mechanical and electrical routes, and the internal fit-out, had to work together as one repeatable, production-ready solution.
The challenge was not simply to manufacture a building. It was to validate the production approach, identify opportunities for improvement and create a strong foundation for future programmes, demonstrating that the system could be successfully scaled to meet anticipated market demand.
Alpha Manufacturing supported the project through panel manufacture, design development, coating process planning, quality assurance and production planning.
Working closely with the UB Infrastructure team, Alpha brought a manufacturing mindset to every stage of the build. The two teams assessed panel interfaces, tolerances, trims, fixings, access points and assembly sequencing, refining the design as the demonstrator unit took shape.
This collaborative approach allowed practical learning to feed directly back into the system. Assembly methods were optimised, manufacturing challenges were addressed and opportunities to improve repeatability were identified ahead of future production.
The demonstrator unit became more than a finished building. It provided a real-world environment in which both teams could test, learn and improve together.
Beyond engineering expertise, Alpha Manufacturing’s production capability provides the resilience needed for infrastructure projects operating to demanding schedules. With manufacturing operating 24 hours a day across all key production areas, the business maintains high-capacity output and rapid turnaround times, ensuring it can respond quickly as projects move from prototype into full-scale manufacture. This responsiveness is further strengthened by the UK’s longest Stopa automated storage system, capable of holding up to 600 tonnes of raw material, allowing material to be readily available for production and minimising delays.
“The relationship has felt collaborative and constructive, with Alpha Manufacturing providing the manufacturing depth and repeatability we need as UBI moves from individual project delivery into higher-volume infrastructure programmes.”
The completed demonstrator unit proved that the UBI system could be manufactured consistently, assembled efficiently and adapted to meet different customer requirements.
The project also identified opportunities to strengthen design for manufacture, introduce robust quality hold points, improve logistics planning and integrate mechanical and electrical requirements earlier in the development process.
Now serving as a showcase for prospective customers, the completed building allows visitors to experience the quality and flexibility of the UBI system first-hand. It provides tangible evidence of what can be achieved when innovative design and manufacturing expertise come together.
For UB Infrastructure, the project has built confidence in both the manufacturing route and the quality of the finished product. It provides a strong platform for future opportunities across rail, utilities, defence and wider infrastructure.
For Alpha Manufacturing, it demonstrates the value of becoming involved early in product development and working alongside customers to turn ambitious concepts into scalable, manufacturing-ready solutions.
Successful prototype development creates the opportunity to test ideas in practice, refine key details and apply what has been learned to strengthen the final solution.
“As with any prototype, there have been useful lessons learned, but the way Alpha Manufacturing has engaged with those lessons has been exactly what we would want from a long-term manufacturing partner.”
The completed building represents an important step forward for UB Infrastructure, but it also marks the beginning of a strong manufacturing partnership.
By combining UB Infrastructure’s innovative system with Alpha Manufacturing’s engineering expertise and significant production capability, the project has created a proven foundation for continued development and future higher-volume infrastructure programmes.
Parcel lockers are rapidly becoming an essential part of the UK’s delivery infrastructure, providing consumers with a convenient, secure, and flexible way to collect their parcels. As demand continues to grow, operators are under increasing pressure to expand their networks quickly, efficiently, and at scale.
While location strategy and user acceptance are key considerations, successful parcel locker rollouts depend heavily on something often overlooked: manufacturing capability.
As projects move from the initial stages to large-scale deployment, businesses need a manufacturing partner capable of delivering consistent quality, reliable lead times, engineering expertise, and a seamless transition from prototype development to full production.
Without the right manufacturing support in place, delays, quality issues, and supply chain disruptions can quickly derail rollout schedules, creating unnecessary challenges for operators striving to meet growing demand. That’s why selecting an experienced manufacturing partner from the outset is essential.
At Alpha Manufacturing, we understand the complexities involved in producing high-volume, precision-engineered products. Our fully integrated manufacturing capabilities allow us to manage every stage of the production process under one roof, from precision sheet metal fabrication and finishing to powder coating and final assembly. This streamlined approach helps maintain quality, improve efficiency, and provide greater control throughout.
Our integrated approach provides customers with a single manufacturing partner capable of supporting projects from initial design and prototyping through to full-scale production. Combined with advanced manufacturing technologies and 24/7 operational capability, our approach enables us to meet demanding production schedules while maintaining the high standards expected of modern parcel locker solutions.
Whether you’re launching a new parcel locker programme or expanding an existing network, having the right manufacturing expertise behind your project can make all the difference. With a reliable partner in place, you can scale with confidence, knowing your manufacturing operations are equipped to support long-term growth.
Looking for a manufacturing partner that can grow alongside your parcel locker projects? Get in Touch
As requirements become more advanced within the electrical and utilities sector, manufacturers are increasingly expected to deliver solutions that combine reliable performance with a refined aesthetic. Electrical and utility units must meet strict compliance standards while integrating seamlessly into their surroundings. At Alpha Manufacturing, we bring together design expertise and precision engineering to ensure every project achieves this balance.
We offer end-to-end capabilities, producing robust and time-tested units. Working across a wide range of specifications, our team creates units tailored to their environment, delivering a consistently high‑quality finish. Essential features such as Louvered Air vents, Knockouts and threaded inserts are engineered with accuracy, and each unit is finished with expertly applied powder coating to meet both visual and functional requirements.
Our turnkey fabrication service brings every stage of production under one roof, creating a streamlined process from concept through to delivery. We can even provide bespoke packaging solutions tailored to individual customer requirements. This approach encompasses, engineering, manufacturing, assembly, testing, and project coordination, enabling us to adapt to projects of varying complexity while maintaining efficiency, quality, and reliability. With extensive experience in multi‑component assemblies, we uphold exceptional quality while meeting the demanding timelines expected across the utilities industry.
This capability is reinforced by our ongoing investment in technology and innovation. Continuous advancements keep us at the forefront of modern manufacturing, enabling exceptional finish quality alongside efficient production speeds. Our advanced CNC machinery delivers the precision and repeatability required for detailed utility designs, ensuring consistent, reliable, and timely output on every project.
We aim to deliver utility solutions that combine durability, compliance, and outstanding visual quality without compromise. Through cutting‑edge machinery, skilled engineering, and a commitment to continuous improvement, Alpha Manufacturing remains a leader in producing high‑performance utility units that meet the evolving demands of today’s premium environments and installations.
Reliable corrosion protection is critical for components operating in demanding environments. At Alpha Manufacturing, durability is considered from the earliest stages of production, ensuring components are supplied with coatings designed to perform long after installation.
By working with advanced powder coating and pre-treatment processes capable of achieving 1,000 hours of salt spray corrosion resistance, Alpha Manufacturing offers customers confidence that their components will withstand harsh operating conditions while maintaining long-term integrity.
Salt spray testing simulates prolonged environmental exposure through continuous saline spray. To meet the 1,000-hour benchmark, corrosion must not exceed 2mm from the scribed area, making it a widely recognised industry standard for long-term performance.
Advanced Pre-Treatment for Long-Term Performance
The foundation of effective corrosion resistance lies in correct surface preparation. Alpha Manufacturing incorporates modern Oxsilan-based pre-treatment technology as part of its coating capability, offering a state-of-the-art alternative to traditional zinc or phosphate systems.
By combining zirconium and silane chemistry, this process forms an ultra-thin protective layer that delivers corrosion resistance comparable to much thicker zinc-phosphate coatings with greater efficiency and reduced environmental impact.
Controlled Processes, Consistent Results
The pre-treatment process follows a tightly controlled, multi-stage system including alkaline cleaning, rinsing with demineralised water, application of Oxsilan pre-paint treatment, and final rinsing prior to coating. This structured approach ensures optimal adhesion, enhanced durability, and consistent results across repeat production.
Process integrity is maintained through daily internal testing, Statistical Process Control (SPC), and regular external verification by Chemetall, the developer of Oxsilan technology. This
ensures quality is monitored proactively at every stage.
Added Value for Alpha Manufacturing Customers
Correct pre-treatment delivers stronger adhesion, extended service life, reduced maintenance requirements, and greater reliability in finished components. As customer specifications increasingly demand 1,000 hours of corrosion resistance, Alpha Manufacturing provides a proven, dependable solution.
By integrating advanced corrosion protection, rigorous quality control, and sustainable processes into its service offering, Alpha Manufacturing adds measurable durability and long-term value to every coated component it supplies.
