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Operational Capability

Since 2007, Eagley Plastics have created a truly robust operation that can handle a diverse range of applications and polymers.

With 26 extrusion lines in operation—including a range of single and twin-screw extruders from 45mm to 110mm—we’re well-equipped to handle a wide variety of PVC and speciality polymer profiles. The facility includes solid wall extrusion, co-extrusion and cellular capabilities, allowing us to support more complex requirements without compromising lead times.

Within the extrusion operation, we operate three umbilical filler lines and five moulding machines.

Our Capabilities
This range gives us the ability to support customers across multiple sectors, from custom profiles and technical mouldings to finished laminated products.

Our throughput ranges from 20kg to 300kg per hour, giving us the flexibility to run small development batches or full-scale production. We’re set up to process over 15,000 metric tonnes per year, and we maintain a minimum of 60% spare capacity to accommodate growth, new projects, and fast-turnaround work when needed.

Everything is backed by a team that understands the materials, the machines, and the expectations that come with modern manufacturing. If you need a production partner who can scale with you, adapt quickly, and support your technical requirements with confidence – Just ASK.

Rigid Extrusion

Our rigid extrusion lines are built for flexibility and performance, capable of running single, twin and quad strand profiles with precision. Whether it’s a lightweight 20g per metre profile or a robust 3kg per metre extrusion, we have the equipment and expertise to deliver consistent, high-quality results. Our broad capabilities make us a trusted partner for everything from intricate technical profiles to large-format extrusions.

With output capacities ranging from 15kg to 260kg per hour, we are well equipped to meet the demands of a wide variety of applications and industries. This range allows us to tailor each production run to your specific requirements, optimising both throughput and material performance. Guided by our Just ASK values of Agility, Service and Knowledge, we ensure that every project receives the attention and technical insight it deserves.

Flexible Extrusion

Our flexible extrusion lines are built for consistency and control, capable of running single strand profiles with precision. Whether it’s a fine 20g per metre section or a heavier 2kg per metre profile, we have the equipment and experience to deliver high-quality flexible extrusions tailored to your exact needs. Our proven capabilities make us a reliable partner for a broad range of flexible profile applications.

With output capacities ranging from 8kg to 200kg per hour, we are well equipped to meet the demands of various sectors and specifications. Every order is handled with the responsiveness, support and technical depth that define our approach. By placing Agility, Service and Knowledge at the core of everything we do, we deliver more than just product — we build trust through dependable performance and informed collaboration.

Co-Extrusion

Our co-extrusion capabilities allow us to combine multiple polymer materials into a single, high-performance profile. By feeding two or more compounds through a shared die, we can produce components that bring together properties such as rigidity and flexibility, or add contrasting colours for functional or aesthetic purposes. This process is ideal for applications like rigid profiles with integrated soft seals or profiles featuring colour-coded identifiers, all produced in one continuous run.

Co-extrusion not only enhances product performance but also streamlines manufacturing by removing the need for additional assembly steps. Whether you’re looking for improved sealing, weather resistance or specialist applications such as hydroscopic properties, our team brings the technical know-how and tooling expertise to deliver precise, reliable results. Aligned with our core values of Agility, Service and Knowledge, we work closely with you to develop solutions that meet both functional demands and commercial expectations.

Cellular Extrusion

Our cellular foam PVC extrusion process offers a smart, lightweight alternative to solid profiles, engineered to reduce material density while maintaining structural strength. These profiles are ideal for wood replacement in applications like window trims, cladding and decorative boards, delivering the benefits of rot resistance, reduced weight and easier handling. If you want to know more, Just ASK.

Injection Moulding

Our injection moulding facility supports the production of high-quality plastic components with precision and repeatability. Through our continuous investment program we have five machines ranging from 50 to 250 tonnes, we can accommodate a wide variety of part sizes and complexities, from small technical mouldings to medium-sized structural components. Whether it’s a standalone part or a component designed to work in harmony with our extruded profiles, we deliver reliable results that meet tight tolerances and demanding specifications.

Recycling Operation

Through our continuous investment program the recycling facility has the capacity to process up to 5,000 tonnes of material per year through granulation and pulverising. We are industry experts at converting recycled materials into finished products. We have worked closely with our customers on a number of recycling initiatives.

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