Bespak Injection Moulding Academy

During a particularly busy period with several concurrent new product projects, it became apparent that Bespak’s resource base of technicians with a high level of technical injection moulding skills was becoming stretched. These skills are fundamental to the industrialisation of inhaled and nasal drug delivery devices that Bespak is known for. As the technical moulding skills base was low across the UK, recruitment of new technicians was proving challenging, and the provision of training to upskill existing employees was in thin supply and therefore high cost and time delayed. This highlighted the need for a completely new approach to developing and maintaining a highly skilled technical moulding skills base in-house.

Solution: There was a clear opportunity for an on-site injection moulding training facility that could increase internal technical skills in a cost-effective way. Tommy Cove, Process Innovation Manager (Injection Moulding), proposed the Injection Moulding Academy (the Academy), an in-house initiative that would enable technical training, skill sharing and individualised development support. The Academy would become a hub offering training in line with RJG standards – the world standard in the industry.

The role of the Academy was clear, and the plan was approved by Bespak’s Board of Directors in 2017. The Academy was initially set up in an unused laboratory with one injection moulding machine. Two additional machines were later supplied on loan from manufacturers, increasing capacity for training.

Following a rigorous selection process, Patryk Bortnik was selected as the lead trainer for the Academy. In addition to achieving RJG Master Moulder Level 3, and a B. Eng. in Polymer Engineering, Patryk possessed the soft skills required to develop and implement training programmes and support to trainees.

The Academy now delivers a wide range of courses to match Bespak’s current and future technical moulding skills needs. The courses go up to RJG Master Moulder Level 1 for technical staff, and also deliver moulding appreciation overviews for the wider Bespak team. Beyond this, the Academy is open to Bespak customers and suppliers, helping to improve injection moulding standards in the industry. Bespak has continued to invest in the Academy since it opened, updating the equipment and facilities, in addition to expanding its training team with the addition of a second trainer in 2022.

Results: Since opening, the Academy has delivered 9,500 training hours to more than 500 individuals, saving over £80,000 in training costs in its first three years. As a result, Bespak’s staff demonstrate high levels of technical skill, leading to a wide range of benefits both internally and for customers.

Scrap rates have been lowered, damage to equipment is reduced and there are fewer defects and accidents. This in turn has led to shorter new tooling validation timelines: the number of tool loops has reduced to an average of 4 trials per tool compared to an average 9 trials per tool in 2017. Bespak has also seen a decrease in mould tool performance qualification validation failures due to more informed decision making.

The range of courses and tailored support offered mean the Academy is pivotal to Bespak’s business growth and its support of customers. The Academy is unique in being able to offer apprenticeships for polymer technicians and in-depth training programmes for engineers transitioning from other industries. These offerings have both supported recruitment and benefit the career development of staff, leading to around £70,000 in recruitment and relocation cost avoidance due to career progression. In addition, several major customers and suppliers have attended training, reflecting the high standards of the Academy and the value it offers to partners. Sharing skills in-house has supported the adoption of new technologies, enabling the business to quickly adapt to new industry demands and trends, ensuring Bespak remains at the forefront.