Automation and ambition power Bonnington Plastics’ boldest evolution yet
As one of the largest and longest running UK importers of home and garden goods, Bonnington Plastics has enjoyed 58 years of success. In the fast-paced post-pandemic world, the company has demonstrated agility and adaptability, bringing on new partners and bursting onto the UK manufacturing scene. As Sales Director, Sergio Tartaglia, begins: “Our imports business has been running since 1967, and in that time the company has seen numerous different evolutions. In recent years, we’ve successfully moved into the online retail and e-commerce space with the Wido part of the business, and we now partner with a couple of online companies who sell all our ranges as well. We deal with multiple retailers, cash and carry operations, and similar services. Our operations have changed considerably over the past decade, a transformation that was spurred on by the pandemic.
“For a long time, our product range was primarily home, gardening tools, camping, pet and pest. We also imported some products for the catering and home furnishing industries. However, with major players in the e-commerce space coming to dominate so many different categories, we had to think strategically. We got the opportunity to work with FlowChem, a couple of years ago, and that partnership became a real turning point for the business.
“FlowChem are a UK based manufacturer of home and garden pet, pest and automotive chemicals. They produce cleaning products, artificial grass, patio and screen wash, and chemicals for car maintenance. The owner of the business wanted to partner with us, as we already had an established customer base in some of these areas, and the infrastructure required to sell and transport products.
“They were new to the business, and it turned into a very fruitful relationship. We provided the experience and industry know-how, and they delivered a whole new range of products. We brought some of their operations into our warehouse and gave them space to work. We also provided manufacturing support, drawing on our experience as a manufacturing business before we pivoted into imports.
“Since then, we’ve gone from strength to strength. We have an established operation, where we mix, bottle, and label chemical products for the FlowChem brand. We also introduced pickers, which are used for selecting products according to the orders we receive and putting them on pallets ready for distribution.
“Joining together with FlowChem has helped us bring several major clients on board over the past year. We’ve now got some significant accounts, which make up a large portion of Bonnington’s business. We’re still bringing in imports, and we’re seeing a regular increase in profits. The business has become a real machine; we’re able to manufacture, package, and deliver products all in one space.”
Investing in new technology has helped Bonnington Plastics re-establish itself as a major UK manufacturer. As Sergio reveals: “One of our biggest products now is screen wash, and so we’ve invested in some new machinery to help manufacture it at higher volumes. Especially coming into winter, when there’s higher demand for screen cleaning products, we want to be prepared. The new technology automates the mixing process, which is an advanced capability. Not many UK manufacturers have the tools to do that, so it sets us apart in that regard.
“On top of that, we’ve just put down a deposit on a blow molding machine, which can produce 250,000 bottles a month. This will really allow Bonnington to become a one-stop-shop, where bottles are produced, filled, labelled, packaged, and shipped.
“FlowChem started off as a back garden operation, with an incredibly small team and no industry connections. To go from that to what could soon be a multi-million-pound operation is no small accomplishment. The new machinery, once it’s all in place, really has the potential to take our business to the next level. 
“We’re even looking to become major competitors to established brands. A lot of the products we’re now selling, such as blue wash, AdBlue and screen cleaner, have been monopolized by one or two manufacturers for a long time. They’ve had the market to themselves, mostly because other UK manufacturers lack the facilities and capacity to produce certain products. But that’s all about to change – we’re in a strong position, and we’re very driven to increase our market share.”
The desire to embrace the benefits of automation has allowed Bonnington Plastics to level up its operation, with more changes planned. As Sergio discusses: “We used to have five 10,000 liter tankers, which we used to store the chemicals. We decided to replace those with 23,000 liter tanks, as this means the entire production line can run for longer.
“The tankers are where it all starts. From there, the chemicals are pumped into a machine which fills the bottles, and those are moved down the manufacturing line on a conveyor belt. The products are then labelled, quality checked and packed onto pallets. Higher capacity means we can produce more bottles per run, before we need to refill or swap over the tanks.
“We currently have a semi-automated operation, with a small team of four or five people overseeing the entire process. Over time, we’d like to find ways of fully automating the manufacturing procedure – we’ll still need people to oversee everything and maintain the machines, but with a greater degree of automation, we will be able to produce quicker and make their jobs safer. For instance, we currently have team members lifting boxes and working closely with chemicals. With automation, we can reduce risk and put their skills to better use, overseeing operations and maximizing efficiency.”
With demand on the rise and big plans for the future, 2025 marks a major milestone in Bonnington Plastics’ legacy. As Sergio concludes: “The main thing for us this year is to get our machinery up and running. To fulfil expectations for September onwards, we’re going to need more people, more space, and greater output. We’re currently operating at maximum capacity, and so our expansion efforts are central to ensuring the future of the business. We need room to grow.
“Since bringing FlowChem on board, it’s been an exciting time for us here at Bonnington Plastics. We’ve revitalized our manufacturing operation and opened ourselves up to a variety of new opportunities. It’s the beginning of a bold new chapter for the business. Watch this space.”