Case Study: Replacing Metal with Plastics

Material replacement can be a challenge, so when Viridian Systems approached Rutland Plastics to replace a metal component with plastic injection moulded alternatives, there were many considerations.

The Challenge

Viridian Systems is a well-established environmental solutions provider based in the North-West of England, supplying goods and technology for the landfill industry. Viridian is renowned for its range of automatic self-regulating VP pumps which assist in the management of landfill leachate. The company was keen to reduce its part weight, but at the same time, it had to be considered that the pumps are manufactured to tight tolerances, high specifications and technical accuracy.

The Solution

The Rutland Plastics Design Team recognised that the plastic material would need to be very strong as the pumps are continually under immense stress. Additionally, it would need to be able to withstand high temperatures and because of chemicals encountered in the leachate, be corrosion resistant. After selecting the most suitable material, it became clear that an exact copy of the original metal design would not offer the strength required. The Rutland team, therefore, worked on a series of part design modifications to give the part greater strength and integrity.

Exceeding Expectations

The final result totally fulfilled and exceeded the customer’s requirements. The success of this part prompted Viridian to explore the replacement of a further component from the same product.

Rutland Plastics was able to design a plastic replacement for the float used in the pump, the manufacture of which had previously produced a large amount of scrap. Rutland Plastics created a highly unusual solution for the material to facilitate the perfect density for the part to function efficiently.

The Rutland team was delighted when Viridian reported that the new plastic parts were more than a match on performance and additionally outperformed the originals quite significantly on cost.

About Rutland Plastics

Rutland Plastics is a privately owned custom injection moulder of quality bespoke products for a wide variety of industries. Formed in 1956, the company has continued to expand on the same site and now operates a factory area exceeding 66,000 square feet, employing over 130 staff members in Oakham, Rutland. The company holds accreditations for quality management (ISO9001), environmental management (ISO14001) and ISO13485 for medical device quality management.

To find out more about Rutland Plastics, or to contact the team, please use the details below, or visit:

rutland plastics logo
Rutland Plastics
01572 723476

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