Previous Winners of the BPF Horners Award for Polymer Innovation and Design

2025: Cubis Systems: PROtrough 350: Reinventing Cable Protection with Polymer Innovation

Cubis Systems won the Horner’s Award for Plastics Innovation & Design with their PROtrough 350, a pioneering polymer-based cable protection system. The judges were impressed by how it delivers a lighter, safer, and more sustainable alternative to traditional concrete systems. By reducing carbon emissions by 80 percent and being adopted across major UK infrastructure projects, PROtrough 350 is a great example of how polymer innovation can drive both environmental and operational benefits.

2024: Loughborough University’s Next-Generation Additive Manufactured Police Body Armour

Loughborough university recognised that body armour development for frontline policing had stagnated, especially regarding knife and spike threats. They also noted that recent developments are typically with limited-to-no consideration of female users or individuals that have body shapes incompatible with traditional sizing - which leads to officers wearing body armour that is uncomfortable and less effective. That’s exactly why they developed and successfully demonstrated both polymer laser sintered and hybrid aramid-laser sintered body armour panels, capable of providing multi-strike protection against knife, spike, and handgun ballistic threats – in line with the UK Home Office’s Body Armour Standard. 

2023: Suscons' Emergency Relief System

Their shelter is made from 75% recycled PVC window and door frames and can be 100% recycled after its 10 year lifespan without significant loss in physical properties, creating a closed loop humanitarian society.

2022: Variable Diameter Dual Directional Flow Air Ring

An innovative system designed to increase productivity of the blown film process by adding additional cooling above the frost line. Global customers who run VarDAR have not only seen the significant benefit of increased productivity, seen reduced scrap levels (reducing waste), but also improved aesthetic appearance - improving efficiencies.

2021 - StaySafe 5-in-1 hand held fire extinguisher

StaySafe 5-in-1 hand held fire extinguisher by LifeSafe Technologies and Plastipak is a lightweight recyclable plastic aerosol fire extinguisher and a more practical and solution compared to traditional metal canister.

2019 - Hotbin Mini

HOTBIN Mini by Engineered Foam Products is a small hot composting bin filling a gap in the composting market for smaller 1-2 person households who want to compost but are restricted by not having enough waste or space or a regular compost bin.

2018 - Thermoplastic Bulkhead

This Thermoplastic Bulkhead is a car component, developed by RLE International, represents a mass saving of 34%, and a cost saving of 10%, when compared to the existing metallic bulkhead typically found in vehicles.. 

2017  - TickleFLEX

TickleFLEX is an insulin injection aid for diabetics. It fits over the disposable needle used by insulin pens and makes the act of injecting safer, easier and more comfortable. The product features a silicon flexure that collapses in a controlled way when pressed against the skin. It then delivers multi-function benefits.

2016 - World's First All Plastic Trumpet

The pTrumpet — the world’s first all-plastic trumpet — was designed by musicians in England and produced by Warwick Music Group.

The pTrumpet is made up of a fully plastic valve system — the first of its kind — with self-lubricating plastic properties. The polymer lead pipe technology is unique, as is the ability to manufacture the lead pipe in one unit.

2015 - Guardian Maritime Limited

This worthy-winning entry was developed by Guardian Maritime Limited, which is owned and run by husband and wife team David and Teresa Stevens.

The product is an industry compliant system and provides 24/7 protection against stowaways, robbery and piracy. It is believed to be the only “undefeated” passive anti-piracy deterrent.

2014 -  Propoints

Smart Seals Propoints were the winners of the Horners Award for Plastics Design and Innovation 2014. 

Propoints were designed to replace existing materials and some techniques, which can cause damage to the tooth and increase the chances of reinfections. Propoints solves these problems; through single cone technology and exact fit engineered sizes, no compaction is required and a Propoints expansive quality eradicates voids in the canal. In addition, Propoints as a plastic, unlike GP (a resin based material most commonly used,) do not degrade over time; reducing the chances of retreatment.

2013 - Airbus A350 XWB Composite Rear Spar

The highly ‘Airbus A350 XWB Composite Rear Spar’, developed by GKN Aerospace, were announced as the winner of the Horners Award for Plastics Design and Innovation 2013. 

GKN Aerospace has developed automated processes for its A350 XWB composite spar and fixed trailing edge assembly programme. The application of state-of-the-art automated fibre placement (AFP) technology, unique to the UK, has allowed GKN Aerospace to produce cost effective repeatable lightweight components with more complex and bespoke geometries.

The judges recognised the substantial "light-weighting" and strength benefits that this Advanced Plastics Composite product brings in safety and fuel economy to the A350 Airbus. Additionally, the Advanced Automated process to manufacture the spar brings tremendous product consistency and major savings in the time and cost of manufacture.  The judges found that it ticked all the boxes for choice of material, product design, product safety, environmental impact and advanced manufacturing.

2012 - The “Birthing Baby”

The “Birthing Baby”, developed jointly by Brightworks Ltd and Limbs and Things Ltd. The Birthing Baby is a new born baby mannequin which is having a growing role in the training of doctors, midwives and nurses and helps to prevent adverse outcomes in childbirth. Training using The Birthing Baby helps eliminate confusion in roles and responsibilities, provides better structure and coordination to the performance of key clinical tasks and improves organization and support. The head, body and limbs are made from RTV Silicone rubber, ABS and water blown polyurethane foam. The flexibility, hardness, density and weight distribution of the skin, limbs and joints closely replicate those of a real baby.

2011 - Cycloc

The judging panel for this year’s Horners Award were greatly impressed by the overall design concept of the winning entry, The “Cycloc” a stylish wall mounted bicycle storage system – designed by Andrew Lang Product Design Ltd.

The product designed by ‘stunningly simple and attractive’ wall mounted bicycle storage system enables a wide variety of bicycle styles to be stored, suspended from either the frame or the seat posts. Cycloc matured the product into an injection moulded product in 2010 to supply mass market demand and to date 95% of the Cyloc’s production is exported globally, with its main markets extending as far as Australia, North America and Europe.

The product has already been awarded several distinguished

2010 - The Easy Clean-Bedside Cabinet

The judging panel for this year’s Horners Award were greatly impressed by the overall design concept of the winning entry, The ‘Easy Clean’ - Beside Cabinet by Kinneir Dufort.

The 'Easy Clean' from Bristol Maid™ was designed to assist in reducing unwanted healthcare associated infections. 

The design reduces the number of hard to reach corners and surfaces without cutting down patient storage.  The rotationally moulded design helps to achieve better standards of hygiene in patient care whilst maximising space, security and flexibility in operation.

2009 - Omlet Ltd

The Beehaus was developed using modern plastics materials to provide bees with a safe, modern home in which to live and makes beekeeping straightforward and fun.

The judges of this year’s Award were greatly impressed by the Omlet Beehaus due to its use of plastics materials to benefit the environment and to address a topical issue, the decline in bee populations. Moreover, Omlet is the first company in the history of the Award to have won twice, having received the Award in 2004 for their ‘Eglu’ plastics Chicken Coop

2008 - Durakerb

A revolutionary, lightweight and environmentally friendly kerbstone system has been announced as the winner of the Horners’ Award for Plastics Design and Innovation 2008.   The judges of the Horners’ Award were greatly impressed by the overall design concept of the ‘Durakerb’ system which is manufactured from a blend of recycled polymers, and aims to help specifiers and contractors comply with Government requirements for sustainable buildings.

Phil Sutton, Managing Director of Durakerb, adds: “We are delighted to have won the Horners Award for Plastics Design and Innovation as we have a strong commitment to the highest standards of environmental performance throughout our entire product range and throughout each product’s entire life cycle. Durakerb is a cost-effective solution not only to the Health & Safety Executive’s Manual Handling Regulations but also to the ever increasing environmental performance targets now commonplace throughout the construction industry.

2007 - Greaves Best Design

A thermoplastics, injection – moulded, powered Golf Trolley was  announced as the winner of the Horners’ Award 2007.
The Golf Trolley has been designed by Greaves Best Design and is manufactured by GoKart Powered Golf. Tooling, moulding and component sourcing is accessed through DT Industries.  Plastics materials are used to great effect in producing an extremely durable, light weight and low maintainance  product which is easily manoeuvrable at all elevations and on golf courses with challenging terrains.

Speaking about the thinking behind the use of plastics in the trolley, John Greaves, Partner of Greaves Best Design, said that ‘the materials selected facilitated innovation in the incorporation of springs, hinges, gears, and integral latches. Tactile qualities could be introduced which enhanced comfort and allowed a firm grip. Overall, as the components were moulded, the number of parts could be reduced with cost savings resulting’.

2006 - Sovrin Plastics

Sovrin Plastics was the winner of the 2006 Horners Award, an honor bestowed annually by the Worshipful Company of Horners and the British Plastics Federation. Sovrin received the honor for the “Syclix” surgical instruments for minimally invasive surgery. The company was recruited to build the tooling for the Syclix device as well as mold and assemble the product.

According to the Federation, “The ‘Syclix’ is a worthy winner of the Horners Award, which recognises innovation in plastics, in its elimination of the ring grip on regular surgical instruments, which can be restricting and tiring for surgeons. Through rolling the instrument with the forefinger and thumb, the jaws of the instrument are controlled with minimal arm movement for 180 degree rotation.”

2005 - Sound Foresight

The UltraCane is an inventive mobility aid for the blind and partially sighted. It works exactly the same way that bats "see" using ultrasonic echoes to provide users with the ability to "feel" objects in their environment through the cane's vibrations. Like the bat, the Ultracane uses ultrasonic echoes (signals that bounce off objects in the vicinity) to detect how big and how far ahead obstacles are and converts this information into vibrating buttons in its handle.

As there are a number of sensors, the can can even detect obstructions at head height. This means that the UltraCane user builds a growing spatial map of their surroundings and all the trials and user feedback suggests that this spatial awareness doesn't even require conscious effort on behalf of the user - it just happens. The additional feelings of safety and confidence reported by users is no doubt because blind and vision-impaired people have been used extensively in developing the UltraCane.

2004 - Omlet Ltd

The EGLU Chicken coop (featured in PRW 4th June 2004) has now also been adapted to accommodate other small animals such as rabbits and hamsters. Seven of the structural components are rotationally moulded by HP Mouldings in HPDE in a range of elegant colors.

The EGLU is more than a cosy, fox-proof hen coop since with its hollow walls it is part of a sustainable food chain. It can be delivered direct to your home, together with a pair of hens and enough food to start them laying eggs. This young company - called Omlet Ltd.- certainly deserves continued success.

2003 - Vent-Axia® Air Minder

One of this year’s most outstanding entries and the ultimate winner was the Vent-Axia® Air Minder. This whole-house heat recovery ventilation system effortlessly removes the home’s polluted air. The main unit had to be light in weight in order to ease installation and plastics became the first choice material. Two ground-breaking design features were developed, firstly the major ABS outer casings were over moulded with expanded polystyrene in order to ease the air flow and improve the insulation and quiet running of the unit and secondly, the traditional bulky aluminium heat exchanger was replaced by an automatically assembled series of concatenated thermoformed PVC baffle plates which now outstrip the performance of metal equivalents. The Air Minder can greatly reduce the energy needed to heat the home and will have a positive environmental impact when installed in new buildings.

2002 - 3M™ Paint Preparation System

A new innovative system for mixing and preparing refinish material prior to spraying. This system features a plastic disposable reservoir and associated fittings which greatly improve the efficiency of the spraying system.

2001 - The World’s first single piece PET can entered by the RPC Containers Ltd.

Judges chose the plastic can because it has revolutionised the way lever-lid containers can be produced and con- quered the limitations posed by current moulding techniques.

2000 - ‘Inventa’

‘Inventa’ – an innovative education aid entered by Valiant Technology Limited which makes extensive use of injec- tion moulded Polystyrene and Polypropylene parts.

1999 - 60 litre Supermarket Shopping Trolley

A new concept design for a 60 litre Supermarket Shopping Trolley which was developed by a consortium including the Industrial Design Consultancy (based in Slough), Dupont Engineering Polymers (based in Hemel Hempstead), Plasto AS (Norway) and Carte 2000 (Australia).