Wittmann Injection Moulding Machine Delivers Energy Savings at Kempston Controls

Kempston Controls, a leading supplier of MEM classic low‑voltage devices and injection moulded components for switchgear, has invested in new manufacturing technology at its Holyhead site. Partnering with Wittmann UK, Kempston has upgraded its production capabilities with the SmartPower 120/525 IMM machine and supporting equipment, ensuring efficiency, sustainability, and long‑term resilience.

Say what you like about the explosion of connectivity, the Internet, AI – there’s just one very basic factor that holds it all together – electricity. Along with death and taxes, nothing seems more certain than a bet on continuing growth in the global grid and related products over the coming years.

Enter the Kempston Controls factory in Holyhead, North Wales: The company makes and supplies high-quality MEM classic low-voltage devices. Kempston also make a range of injection moulded components for low voltage switchgear.

In response to increased demand, the Holyhead site recently undertook a review and a major upgrade of its manufacturing capabilities.

David Rees, Group Operations Director at Kempston Controls (Manufacturing), says that “we have had a fleet of Battenfeld injection moulding machines (IMMs) on site here for over 30 years. We therefore know the machines pretty well!”

It came time to invest once more, and we ended up going back to the same IMM technology, now owned and improved by Wittmann. The Wittmann machines are very competitively priced, and the quality build speaks for itself.

Wittmann UK supplied a SmartPower 120/525 IMM machine, and the total production cell package included a Dosimax metering unit, Feedmax S3 hopper loader and Tempro Primus C90.

Orrin Smith, Wittmann UK Area Sales Manager, says that “with so much competition on this project, it was great to come out on top and help keep our thirty-year relationship going. Not only that, but our Wittmann SmartPower 120 machine topped the ratings in all key areas: lowest energy usage, smallest footprint, fastest cycle time – all at a very competitive price.”

Orrin adds that “working with Kempston was a treat – since the company had all their technical data lined up and ready for me to assess, prior to us putting our best solution forward.”

As befits a key supplier to the energy markets, Kempston Controls was extremely aware of a very particular bonus in store by sourcing Wittmann, namely the dramatic energy savings made possible via the new Wittmann IMM designs.

David notes that “energy use is a big deal for us. Low running costs for our plant are very important, particularly with the high energy costs being charged in the UK. Since the machine replacement, we have closely monitored the changes in energy usage. I am very happy to note that the new SmartPower 120 runs on 60% less electricity than previously – thanks to the Wittmann improvements in the machine design.”

Once Kempston’s SmartPower 120 purchasing decision was made, the “delivery, positioning by Flegg Projects, installation and commissioning was flawless,” according to David.

He says that “we were literally operational the very next day – producing components already, with a real buzz on the shopfloor.”

David adds that “the training on the new control system was good, and easy to follow on the HMI screen, which included a very user-friendly manual as an integral part. Our injection moulding team picked it up in no time at all.”

In summary, Kempston Controls made the transition and upgrade from Battenfeld to Wittmann seamlessly. The chances are good that this much heralded move will be repeated similarly in the coming months.

Read more from Wittmann Battenfeld here.

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