Posted by Marketing on October 15 2020

Orthoplastics: Part of the Viant Corporation

Orthoplastics is dedicated to the medical industry and is a world leader in the development and supply of both implantable-grade plastics and also biocompatible plastics for instrument applications.

We manufacture implantable plastics, producing the highest grade orthopaedic UHMWPE and medical devices on the market. Our product development expertise is trusted and proven, with our implantable plastics used in orthopaedic implant applications such as knees, hips and shoulders.

As a part of the Viant corporation, our long term strategic goals at Orthoplastics are to become a true, end-to-end partner for an efficient supply chain solution.

About Viant

Viant is focussed on providing end-to-end solutions for medical device OEMs. Their deep materials expertise, including metals, combined with our experience in engineering, manufacturing, assembly, packaging, and sterilisation allows us to bring our customers’ medical technology solutions to market.

With over 25 worldwide locations and around 425 precision machining centres, Viant is well-positioned to serve its OEM partners and are at the forefront of orthopaedics. With deep expertise in both plastic and metal materials, they provide complete solutions including:

● Implants: low- to high-volume manufacturing; advanced coating capabilities
● Instruments: traditional and robotic; reusable and single use
● Delivery systems: best-in-class design; low- to high-volume manufacturing

Commitment to quality

At Orthoplastics, quality encompasses everything across all aspects of production, from customer service, to design and manufacture of its premium grade medical plastics.

As part of the Viant corporation, quality is at the forefront of what we do every day because our components and finished devices save or enhance lives every day and help medical professionals achieve better outcomes for patients.

To emphasise this strict focus on delivering the highest grade of UHMWPE products, Orthoplastics adhere to rigorous quality inspection standards and processes. This ensures that every product that leaves its facility is guaranteed to meet and exceed customers demanding standards.

As a result, Orthoplastics have been accredited to a wide range of International Quality Standards. Paying full attention towards the customer and the product ensures that Orthoplastics fully understand the needs of their clients, even down to the packaging and delivery of the product.

Orthoplastics Limited is dedicated to the medical industry and is a world leader in the development and supply of both implantable grade plastics and also biocompatible plastics for instrument applications. Get in touch with us to discuss your requirements and discover how we can help.

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Posted by Marketing on October 08 2020

Orthoplastics: We’ve Extended our Instrument Materials

Orthoplastics has been a manufacturer of instrument materials since 2002, recently we have invested in new manufacturing capabilities which adhere to the latest international standards. Our investment of time and resources into innovation has created a platform whereby Orthoplastics can continue to improve on its high quality, industry-leading products.

Here at Orthoplastics, we have extended our materials offering with Polyacetal (Hostaform) and Polyphenylsulphone (Radel).

Hostaform© is the latest offering from Celanese healthcare, a long term replacement for its legacy Celcon portfolio, this material complies to ASTM F1855 and is available in a wide range of colours to meet the demand for high-quality instrument applications and improve quality in coloured molded parts.

Using Hostaform for coloured parts delivers increased polymer stability due to reduced heat history during the preparation of the coloured polymer, improved colour distribution throughout the injection molding process and reduces risks in medical innovations with stable, high-quality and regulatory compliant colours.

Radel©, Solvay’s high-performance resin has been available for use in the medical sector for many years. Orthoplastics recently worked with Solvay to develop the extensive validations for the manufacture of the extruded bar stock. Again, the wide range of colours meets the industry demands for identification, traceability and long-term performance.

Radel polyphenylsulfone (PPSU) can withstand continuous exposure to moisture and high temperatures and still absorb tremendous impact without cracking or breaking.

All materials are available in standards 5ft (1525mm) lengths and a diameter range from 1”(25.4mm) – 4”(101.6mm)

Industry-leading systems & facilities

Orthoplastics’ industry-leading facilities are situated around 50 kilometres north of the city of Manchester. Its impressive facilities offer a combined size that exceeds 50,000 square feet.

Firstly, Orthoplastics 30,000 square foot unit contains a range of different departments including machining, finishing, research & development, shipping and warehousing space. Additionally, a 20,000 square foot press facility has been purpose built in order to house the state of the art UHMWPE press that has been installed at Orthoplastics and offers an exceptional quality of finish on all products manufactured.

Orthoplastics Limited is dedicated to the medical industry and is a world leader in the development and supply of both implantable grade plastics and also biocompatible plastics for instrument applications. Get in touch with us to discuss your requirements and discover how we can help.

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Posted by Marketing on July 28 2020

Quality Management System Statement

During the COVID-19 outbreak, Orthoplastics have adapted their current working practices to ensure that all aspects of our accredited QMS and regulatory and compliance activates are adhered to, despite current restrictions in place.

Orthoplastics is fortunate enough to already have an electronic QMS in place, which has made working remotely and ensuring compliance to standards more accessible for our Quality Management team.

Orthoplastics is working closely with accreditation bodies to ensure our quality management systems are maintained and reviewed remotely. We are extremely proud of how we have continued our high-quality standards, as well as our robust Quality Management System during this time.

We are pleased to announce that we have been accredited to ISO 17025:2017, which has been achieved by remote based working.

As a medical device supplier, many of our customers require a supplier audit to be performed periodically. As such we have adapted our audit process internally and externally to ensure the safety of our employees, customers and suppliers.

We are now offering our customers desktop and virtual audits of all aspects of our Quality Management System, until at least 2021. To arrange a desktop / virtual audit please contact Rebecca Field by email at field@orthoplastics.com

Despite these uncertain times, Orthoplastics remain dedicated to the continued conformity of all its quality management systems ensuring product quality is at the forefront of all working practices.

Committed to Delivering the Highest Quality Standards

At Orthoplastics, quality is at the core of everything we do and covers all aspects of production, customer service, design and the manufacture of our premium-grade medical plastics.

To emphasise this strict focus on delivering the highest grade of UHMWPE products, Orthoplastics adhere to rigorous quality inspection standards and processes. This ensures that every product that leaves its facility is guaranteed to meet and exceed customers demanding standards.

As a result of this devoted approach towards quality, Orthoplastics have been accredited to a wide range of International Quality Standards.

Employing traceability techniques during the manufacturing of all medical-grade product, allows Orthoplastics to regularly assess product quality. All data is recorded and stored for a minimum of 30 years after the manufacturing processes.

Additionally, implementing visual inspection techniques allows for the determination of the products’ quality, along with using non-destructive, ultrasonic testing. Product batch testing is then completed in accordance with ISO 5834-2, ASTM F648 and customer specifications.

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Posted by Marketing on July 21 2020

What’s Been Happening at Orthoplastics in 2020

2020 has been a year like no other and we’re only just over halfway through. From torrential rain to a heatwave the weather has certainly been unpredictable and challenging.

The COVID pandemic and lockdown brought challenges that many of us didn’t expect and we all had to learn to adapt quickly, not only professionally but personally too. That said, here at Orthoplastics, we have some exciting news that we are proud to share with you.

New Manufacturing Facility Update

Back in September of last year, we announced plans for the opening of an additional manufacturing facility in the UK and we’re pleased to have an update on the progress of the new building at the Futures Business Park Development in Rossendale.

As with all complex builds, the path to completion never runs smooth and this build hasn’t been an exception, but we’re pleased with how it is progressing.



The new build at Futures Park continues at a pace with the partial completion handover being 10th July for the internals only 2 weeks over schedule, but given the weather and COVID, this is an excellent result.

Whilst the internals will be finished, it will be a further 2 weeks for all external works such as car parks and landscaping to be complete and they should be finished by the end of July 2020.

The building completion is excellent, but we have encountered delays on the press build due to the COVID lockdown and travel restrictions. Approximately 25% of the press build is complete and the remaining build is estimated to take around 10-15 days once the engineers return.

Progress Update on Apprentices

As education has been one of the biggest areas that has been impacted by COVID, it was inevitable that apprenticeships would be affected during these unprecedented times.

We’re pleased to say that colleges such as Burnley College were quick to respond and adapt and offered remote learning for the apprentices that usually attend college for their day release qualification and special measures have been put in place to overcome the challenges of workplace assessments.

Here at Orthoplastics, we have been encouraging our apprentices to continue with their studies during lockdown.

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Posted by Oliver on May 26 2020

Queen’s Awards Win Opens the Door to New Opportunities for Orthoplastics

During a time of uncertainty and unrest across the country and around the globe, being awarded the Queen’s Awards for Enterprise and International Trade couldn’t have come at a better time to boost staff morale.

The whole team here at Orthoplastics are incredibly proud that their hard work, commitment and determination has been recognised with such a prestigious award.

The awards celebrate the success of exciting and innovative businesses which are leading the way with pioneering products or services, delivering impressive social mobility programmes or showing their commitment to excellent sustainable development practices.

Increased recognition nationally and internationally

Sales and Marketing Director, Bernadette Dabbs says “not only has the Queen’s Award given a great boost to staff morale during these uncertain times, but it also opens the door to new opportunities for Orthoplastics both nationally and internationally.

Recognised around the world as the royal seal of approval, it’s the highest accolade any UK business can achieve and will help us drive forward our international marketing efforts and raise the profile of the business.

Use of the Queen’s Award emblem in our marketing materials will help us reinforce our achievement and gain a competitive edge. It also opens the door to increased press coverage not only at home but abroad too. It’s an exciting time here at Orthoplastics.”

A great boost for the company

Mark Allen, Managing Director at Orthoplastics says “I’m am incredibly proud of the team. Winning this award is testament to the hard work and commitment of everyone here at Orthoplastics. News of the award has really given a boost to morale across the board.

Getting the royal seal of approval confirms that Orthoplastics is a leader in the manufacture of medical-grade plastics for the medical sector and the award will help us gain recognition around the world and open up new opportunities for us as a company.

Everyone here should be proud of the achievement and we are all looking forward to the award presentation.”

Orthoplastics is a fully dedicated end-to-end solution provider to the medical sector and has developed an international presence with over 350 global OEM’s producing implantable orthopaedic products.

Orthoplastics’ expert knowledge of orthopaedic materials has been developed continuously and our vision of becoming the industry’s leading manufacturer of medical-grade plastics has been achieved through our unsurpassed dedication to quality and excellence.

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Posted by Oliver on May 05 2020

A History of the Queen’s Awards for Enterprise

Following the announcement of our delight at being awarded the prestigious Queen’s Awards for Enterprise and International Trade, we wanted to share with you a history of the Queen’s Awards.

When where the Queen’s Awards established?

The Queen's Awards for Enterprise is an awards programme for British businesses and other organisations who excel at international trade, innovation or sustainable development. It’s the highest official UK award a British business can be awarded.

The scheme was established as The Queen’s Awards to Industry in 1965 and included The Queen's Awards for Export, Export Achievement, Technology, Technological Achievement and Environmental Achievement. Until 2017, when it was rested, the scheme also included an award for individuals known as the Queen’s Award for Enterprise Promotion.

The Queen's Award to Industry became the Queen's Awards for Export and Technology in 1975, with Environmental Achievement added in 1992. In 1999, the scheme became the Queen's Awards for Enterprise with International Trade, Innovation and Sustainable Development as the categories. In 2017, a fourth category was introduced, Promoting Opportunity (through social mobility).

Eligibility to enter the Queen’s Award for Enterprise

To apply for the Queen’s Award for Enterprise your organisation must:

● Your organisation can be a business or non-profit and be based in the UK (including the Channel Islands and the Isle of Man)

● Tile its Company Tax Returns with HM Revenue and Customs (HMRC)

● Be a self-contained enterprise that markets its own products or services and is under its own management

● Have at least 2 full-time UK employees or part-time equivalents

● Demonstrate strong corporate social responsibility

The Queen’s Award for Enterprise 2020

Since the awards were first established over 7000 companies have achieved a Queen’s Awards, including Orthoplastics who were awarded the Queen’s Awards for Enterprise and International Trade 2020.

Now in its 54th year, the Queen’s Awards for Enterprise remain the most prestigious business awards in the country, with winning businesses able to use the esteemed Queen’s Awards emblem for a five year period. Bringing with it more recognition, nationally and internationally and greater opportunities.

This year 220 UK businesses have been recognised for their contribution to International Trade, Innovation, Sustainable Development and Promoting Opportunity (through Social Mobility).

The Queen’s Awards for Enterprise 2020 include:

● 128 awards for International Trade
● 66 awards for Innovation
● 19 awards for Sustainable Development
● 7 awards for Promoting Opportunity (through Social Mobility)

What happens if your company wins?

The Queen’s Award is valid for five years and winning organisations will benefit from being able to fly the Queen’s Award flag at their principal premises, use of the emblem on their stationery, advertising and goods and Global recognition and commercial value for your business.

Winning a Queen’s Award for Enterprise will also help your company gain a competitive edge and will open up new business opportunities. In addition, winning the highest UK business award can provide a great boost to staff morale.

Winning businesses will be presented with the award at the winners’ premises by the Lord-Lieutenant of the County as HM The Queen’s representative. The Awards consist of a Grant of Appointment and a presentational item bearing the Emblem. Representatives of the winning businesses will also be invited to a celebratory Royal Reception.

We are extremely proud to be awarded our first Queen’s Awards for Enterprise and International trade. The award was confirmed on Tuesday 21st April and is an outstanding achievement for the company.

Managing Director Mark Allen says “this is a fantastic achievement for the whole team at Orthoplastics and is a true testament to the hard work and dedication of everyone here. Being awarded such a prestigious award is a great morale boost and will open the door to many new opportunities. We’re looking forward to the award presentation and attending the Royal Reception.”

The award is recognition of Orthoplastics being the leading manufacturer of medical-grade plastics, which has been achieved through our unsurpassed dedication to quality and excellence. Investing both time and resources into developing our knowledge of medical plastics and advanced manufacturing techniques has enabled us to continually surpass our customers exacting standards.

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Posted by Oliver on April 28 2020

Orthoplastics awarded Queen’s Awards for Enterprise and International Trade

We are extremely proud to announce Orthoplastics has been awarded our first Queen’s Awards for Enterprise and International trade.

Orthoplastics is a fully dedicated end-to-end solution provider to the medical sector and has developed an international presence with over 350 global OEM’s producing implantable orthopaedic products.

Orthoplastics’ expert knowledge of orthopaedic materials has been developed continuously and our vision of becoming the industry’s leading manufacturer of medical-grade plastics has been achieved through our unsurpassed dedication to quality and excellence.

Investing both time and resources into developing our knowledge of medical plastics and advanced manufacturing techniques has enabled us to continually surpass our customers exacting standards.

Science making a material difference

Our products were initially pioneered in the UK around 1969 for orthopaedic applications and have over 50 years of successful clinical history throughout the world.

Orthoplastics has been supplying materials for life-changing surgeries since 1996 and has led the way in making recognisable contributions to joint replacement. Our motto ‘science making a material difference’ truly promises an extended product life span and a greatly improved quality of life for patients that receive orthopaedic implants.

In recent years, orthopaedic device manufacturers have identified UHMWPE as the most suitable orthopaedic material to use when creating medical-grade applications for the health sector.

Orthoplastics have drawn upon its industry expertise in medical plastics to provide a series of integrated processes to produce the highest quality of UHMWPE in the world. It’s this premium-grade product that is now the material of choice for orthopaedic device manufacturers across the globe.

Its advanced industry knowledge provides Orthoplastics with the opportunity to continually develop and manufacture innovative product solutions for the medical industry.

An outstanding achievement

We are extremely proud to be awarded our first Queen’s Awards for Enterprise and International trade. The award was confirmed on Tuesday 21st April and is an outstanding achievement for the whole team.

Managing Director Mark Allen says “winning such a prestigious award confirms that Orthoplastics is a leader in the manufacture of medical-grade plastics for the medical sector. The Queen’s Award for Enterprise is the highest accolade for British businesses, bringing with it a host of new opportunities and recognition nationally and internationally.”

The Queen’s Awards for Enterprise are the most prestigious business awards in the UK. The awards were first established in 1965 and since then over 7000 companies have achieved a Queen’s Awards.

The awards celebrate the success of exciting and innovative businesses which are leading the way with pioneering products or services, delivering impressive social mobility programmes or showing their commitment to excellent sustainable development practices.

We are uniquely placed to service global providers with not just materials, but semi-finished devices manufactured in a highly regulated environment using bespoke process techniques. As part of the ‘Viant Inc’ group, our depth of knowledge and capabilities will enhance patients’ lives forever.

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Posted by Marketing on April 14 2020

COVID19 Update: Partial Operations Resumed

Dear Valued Customer,

Following our recent temporary closure of the facility due to the COVID19 crisis, we would like to provide you with an update

The Orthoplastics facility resumed partial operations as of 14th April.

All functions within the building are operating on limited resources to protect our employees and adhere to the latest government guidance. Obviously during this time, the team will be working through the backlog in manufacturing and e-mails, so we would appreciate your patience.

We thank you for your understanding through this incredibly challenging time and we truly appreciate your messages of support throughout what has been a difficult situation.

Please take care of yourself, your family and we wish all those key workers on the front-line safe passage through the unprecedented circumstances.


Mark Allen

Mark Allen
Managing Director

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Posted by Marketing on March 24 2020

COVID-19: Manufacturing Facility Closed

Dear Valued Customer,

Due to the escalating situation relating to the COVID-19 virus and the recent Government guidelines, the facility will be closed as of 22:00hrs 23 March 2020.

This is not a decision we take lightly, but one made with the well-being and safety of our employee’s paramount in our minds. Obviously, this will have a significant impact on our customers and supply chain management, for which apologies and hope that you understand the reasons for such dramatic action.

During this time, there will be a task force of personnel who will be working remotely to ensure that this suspension in activities is subject to review during the rapidly changing circumstances. We will continue to follow government guidelines and provide regular updates through our website new page.

We thank you for your understanding through this incredibly challenging time and we look forward to resuming our business cooperation when it is safe to do so. Please take care of yourself, your family and we wish all those key workers on the front line safe passage through the unprecedented circumstances.

Mark Allen

Mark Allen
Managing Director

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Posted by Marketing on March 19 2020

CORONAVIRUS (COVID-19): WHAT WE ARE DOING?

Dear Valued Customer,

Orthoplastics Limited takes the growing concerns around the COVID-19 virus very seriously, and is monitoring the outbreak, and its potential impact to our business, very closely. Our primary focus at this time is to ensure the safety of our team members, while ensuring that we continue to deliver the highest quality products to our customers and the patients who rely on them.

At this time, we have not seen any impact to our day-to-day business activities. Orthoplastics has formed a task force whose primary goal is to monitor this outbreak and to ensure that regular and consistent guidance is being provided to our teams. We have designated primary points of contact to ensure that information is being appropriately communicated. In addition, to ensure that our focus on delivering products is not compromised, we have taken the following actions:


  • Business continuity planning relating to COVID-19 is in place to ensure that we are prepared to handle situations that may arise


  • Travel guidelines and restrictions are in place


  • Guidelines have been provided to our teams that cover, among other topics, health and hygiene and additional required facility cleaning, as well as best practices


  • We are limiting visitors to our facilities


  • We are encouraging that meetings take place via video or teleconference rather than in person


  • We have suspended attendance at large conferences and meetings




In addition, we are working closely with our suppliers to ensure that they, too, have implemented appropriate measures to ensure continuity of supply. We appreciate that this is a very fluid matter, with new developments being reported daily. We will continue to monitor this situation with the utmost diligence with the goal of ensuring continuity of supply to our valued customers.

On behalf of all of us at Orthoplastics, thank you for your continued business.

Mark Allen

Mark Allen
Managing Director

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Posted by Marketing on February 10 2020

New Manufacturing Facility to be Completed by Summer 2020

In September 2019 we announced plans for the opening of an additional manufacturing facility in the UK, it’s been a busy six months for us and we’re excited to update you on the progress of the new building at the Futures Business Park Development in Rossendale.

As with all complex builds, the path to completion has not been a smooth one but we are pleased with the progress we have made and are on target for the facility to be in operation by late summer 2020.

Overcoming challenges of a complex build

As this is not your normal build and there are many complex factors that need to be considered there have been some challenges for us to overcome. One of the biggest challenges we have faced is the size of the hydraulic press and how it will be placed in the building.

The press which is being manufactured in Slovenia weighs 277,300 KGs and will be delivered to us here in Rossendale on 14 articulated vehicles and re-built onsite. Business Development Director at Orthoplastics, Neil Anderton has been overseeing the development and recently visited Slovenia to approve the thermal press for compression moulded sheet material.



Given the size of the press, it will sit in a pit that is the size of an Olympic swimming pool. The planning around this has led to much collaboration between Orthoplastics, our architects and contractors to help us not only overcome immediate challenges but to also foresee future issues and future-proof the building.

A two-phase approach

The building works are being carried out over two stages. The partial completion of the building is on schedule to be complete for the end of February. Once this first stage is complete the press will be delivered from Slovenia and sited in March/April, allowing for the final stage of building to be completed by the end of June.



Following the successful completion of the building, the facility will be ready to begin manufacturing from August and will enable Orthoplastics to further increase its market capabilities with over £5 million of investment annually.

Mark Allen, Managing Director, Orthoplastics said: “This significant investment underlines our belief that there is huge potential for innovation and growth within the Orthopaedic sector. It is also the next step towards achieving our ambition of pioneering improved patient outcomes and the longevity of implantable medical devices.”

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Posted by Oliver on January 22 2020

Developing our Direct Compression Moulding Capabilities

Orthoplastics has focused on advanced methods of manufacturing UHMWPE and is a World leader in Direct Compression Moulding technology with over 30 years’ experience of orthopaedic plastic manufacturing.

As we strive to improve patient outcomes through innovation, we are excited to announce that we have expanded our direct compression moulding capability with the addition of 5 brand new machines during the last quarter of 2019 to help us advance orthopaedic developments as well as respond to growing market demands and patient expectations.

This decision is part of a long-term business strategy focused on introducing new and improved manufacturing technologies.

Managing Director, Mark Allen said, “We have always been clear that we want Orthoplastics to be known not just as a leading manufacturer and supplier of UHMWPE, but a business that is making recognised contributions to the advancement of the product and its applications across the world.”

Our investment in equipment, technology and in-house capabilities is part of our bigger vision to be at the forefront of setting standards and making new breakthroughs when it comes to manufacturing and designing materials for wide-ranging orthopaedic applications.

Our ultimate aim is to be the best it can be when it comes to innovative UHMWPE design and manufacturing techniques and to ensure that its materials and processes support the manufacture of Orthopaedic limbs and components that can improve the quality of lives for patients through extended product life span, quality and strength.

Creating components with a high gloss finish

Although Direct Compression Moulding is known to be a relatively expensive method of sintering the polymer, it produces components with a high gloss finish.

We have focused on advancing this method of manufacturing UHMWPE to ensure that components produced this way are optimised. We have also pioneered the development of an ‘insert moulding’ process, which allows UHMWPE to be moulded onto or into another steel, titanium or ceramic part.

Medical grade moulding of individual components

Direct Compression Moulding has the capability to produce products which cannot currently be produced, pushing the design envelope for medical grade orthopaedic components. Each component is individually moulded, allowing the finite controlling of all aspects of pressure, temperature and time, during critical consolidation.

By focusing on innovation, this method of manufacture has produced unique over moulding capabilities to produce Mono block components that have a high gloss moulded surface. These design and aesthetically pleasing products provide an alternative market solution to any OEM’s portfolio.

Our Direct Moulding Services

Our Direct Compression Moulding services are at the forefront of new product development. Using our technological expertise, we can bring to market new innovative product solutions to address failure modes typical within orthopaedic implants

Although the technology has been in existence since the 1990's, the new generation of technologies which have been invested in, particularly the 3D printer, allows printed metals and other porous metals technologies to be created.

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Posted by Marketing on January 08 2020

Orthoplastics Win Two Awards at the Rossendale Business Awards

We are very proud to announce that we have won ‘Business of the Year’ and ‘Employer of the Year’ at the Rossendale Business Awards. This is a great achievement for all of us at Orthoplastics and demonstrates our investment in innovation, our people and our processes to become a Company of Choice.

Organised by Valley at Work, the Rossendale Business Awards is an annual showcase for the achievements, quality and diversity of the local businesses and enterprising people who make Rossendale such a great place to live, work and visit.

This year was the 10th annual Rossendale Business Awards and the ceremony was packed with finalists, sponsors and supporters for a great evening.

There was some tough competition in both categories and we are delighted to have been awarded not only ‘Business of the Year’ but also ‘Employer of the Year’. To win two such highly regarded awards shows that Orthoplastics is a forward-thinking company that has a strong focus on its people.

Our Business Development Director, Neil Anderton attended the awards ceremony on the 4th Dec 2019 at the Riverside in Whitworth and was proud to accept the awards on behalf of everyone at Orthoplastics.

“We see our employees as the business. All employees are aware they can voice their opinions and concerns at any time and they will be heard and actioned. We offer a family atmosphere however work to a corporate standard.

As technology moves forward, we strongly believe investment in our employees is paramount, by identifying the strengths and weakness of our employees we have been able to upskill and redeploy employees to ensure they are working to their strengths.

We feel innovation is at the heart of the future of UK manufacturing, and we continue to provide our customers with the confidence in our long-term investments strategy, whilst demonstrating our strategic partnership and commitment,” Neil Anderton , Business Development Director.

Our recent wins are a great accolade for us and a fantastic way to end 2019. We look forward to next year’s awards ceremony.

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Posted by Marketing on December 11 2019

A Look Back at 2019 and What’s in Store for 2020

It’s been a busy and exciting year for us here at Orthoplastics and we’d like to thank all our loyal customers for their continued support and take the opportunity to welcome new customers that have come on board.

During 2019 we have achieved many great things and our continued growth has positioned us well for 2020 and beyond. From encouraging females into engineering through employment, work experience and apprenticeship opportunities to continued staff development and collaboration opportunities.

Here are some key highlights of our achievements in 2019:

● We reached 200 employees during the summer and plan to continue recruiting.

● Our Managing Director, Mark Allen had the honour of giving a keynote speech at the 9th Annual UHMWPE Conference.

● 4 Engineering Apprentices joined Orthoplastics and began college courses in September.

● All 39 employees who attended the Highfield Level 2 Award in Health and Safety within the Workplace achieved a Pass, with 3 attendees achieving 100% in the exam.

● We began talks with Lancaster University to explore the potential for setting up a long-term collaborative partnership.

● We began rolling out Lean training across the business to all employees to ensure everyone has a good baseline understanding of dealing with challenges in the leanest manner.

Looking Ahead to 2020

As 2019 draws to a close, we look ahead to 2020 and the exciting developments we have planned. The first quarter of 2020 will see the opening of an additional manufacturing facility in the UK, set to open in February 2020, the new building will enable us to increase our market capabilities with over £5 million of investment annually.

The new facility at the Futures Business Park Development in Rossendale will fast become a centre of excellence for our business and a launch pad for our extensive global growth plans to support plans to be the world-leader in polymeric solutions.

Mark Allen, Managing Director, Orthoplastics said: “This significant investment underlines our belief that there is huge potential for innovation and growth within the Orthopaedic sector. It is also the next step towards achieving our ambition of pioneering improved patient outcomes and the longevity of implantable medical devices.”

The expansion is expected to create around 100 new jobs within the local community and is fully supported by our US parent company, Viant Inc.

Supporting our business expansion, we have also been quality planning ahead for 2020. Our teams have been thinking about all aspects of quality within a new manufacturing area. By forward planning, we are ensuring that our Quality Management System is at the forefront of our plans for Orthoplastics expansion.

We are in the process of validating our Quality management software, by updating our current software to a web-based version. By doing so we are still maintaining all aspects of the quality management system, such as document, audit and corrective action management, but will also enable greater functionality between users, particularly between various sites.

Dates for the Calendar in 2020

We will be attending various events around the world throughout the year. Some key dates for your calendar include:

24 - 28th March - AAOS Annual Meeting in Orlando, FL, USA

9th -11th June - 16th Annual Orthopaedic Manufacturing and Technology Exposition and Conference in Chicago, IL, USA

23rd-26th September - ISTA 2020 Maui in Maui, USA

We’d like to wish all our customers, suppliers and contacts a very Merry Christmas and a prosperous New Year from everyone here at Orthoplastics. We look forward to continuing working with you in 2020.

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Posted by Marketing on November 18 2019

What’s Been Happening at Orthoplastics in 2019?

It’s been a busy 2019 at Orthoplastics so far, there have been lots of exciting developments, collaboration opportunities and we have continued to focus on employee development. Here are some highlights of what has been happening at Orthoplastics this year.

Lancaster University Visit

Orthoplastics recently spent the day at Lancaster University to explore the potential for setting up a long-term collaborative partnership. The day began with us giving a general overview explaining what it is Orthoplastics does and the services we provide, and where we are heading as an organisation in terms of our future plans and aspirations.

The remainder of the day was spent attending several networking sessions with various departmental leads in order to gauge whether the university can potentially slot in with our organisation’s strategic needs.

The idea was to explore potential projects which will benefit both Orthoplastics and Lancaster University, and we were able to chat with the leads from several faculties including the Data Science Institute, the Engineering Faculty, the Management School, as well as the leads from the Knowledge Transfer Partnerships, Employer Engagement and the lead regarding Student Placements.

The discussions were extremely informative and have allowed us to begin to look into ways in which we can create a mutually beneficial future relationship.

Continued Staff Development

At Orthoplastics, we are committed to ensuring our staff have access to the training they need to further develop their skills and knowledge and enhance their work performance. We are currently rolling out Lean training across the business to 204 employees to ensure everyone has a good baseline understanding of dealing with challenges in the leanest manner.

Our Operational Excellence Manager, Paul Gordon is rolling out the training and with around 40-50% of the team having undertaken the training, he has received some great feedback on the course.

In addition to our Lean training, Team Leader and Customer Services NVQ’s are taking place at co-ordinator and team leader level across the business. We currently have around 10-15 employees undertaking the NVQ’s and will continue to roll them out until all relevant staff have obtained the qualification.

Getting Females into Engineering

Females entering the engineering sector has been a hot topic for the last few years, and here at Orthoplastics we fully support and encourage those who want to work with us or experience what a career in engineering could be like through employment, apprenticeship and work experience opportunities.

We’ve recently welcomed a female Miller to the Orthoplastics team and Lauren Schofield recently completed her apprenticeship with us and is now continuing with her HNC in Engineering. We’re looking forward to welcoming a female student from Burnley College who will be joining us for a work experience placement.

Our work experience and apprenticeship opportunities give those who undertake them a first-hand insight into what a career in engineering involves and can be a great way to introduce engineering to the younger generation.

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Posted by Marketing on November 11 2019

Quality Planning Ahead for 2020

Orthoplastics development of a new facility planned for 2020, has had the Quality Team thinking about all aspects of Quality within a new manufacturing area. The new building, set to open in February 2020, will enable Orthoplastics to further increase its market capabilities with over £5 million of investment annually.

This is a significant move for the business in a rapidly advancing and innovative market and one that is fully supported by US parent company, Viant Inc. By planning ahead, we are already thinking about our Quality Management system, and how we can utilise this at the new facility.

We are in the process of validating our Quality management software, by updating our current software to a web-based version. By doing so we are still maintaining all aspects of the quality management system, such as document, audit and corrective action management, but will also enable greater functionality between users, particularly between various sites.

By forward planning, we are ensuring that our Quality Management System is at the forefront of our plans for Orthoplastics expansion. Incorporation of SQDC (Safety, Quality Delivery, cost) into manufacturing areas throughout the organisation has enabled manufacturing areas to be at the forefront of collecting quality data and reviewing improvement solutions.

Our Quality team are using data collected from SQDC techniques to refocus our continuous improvement strategy and use of the SQDC tool will align Orthoplastics quality management system and improve communication of quality-related activities to all employees, driving our values into each department.

Achievements of Quality Systems and Accreditations

At Orthoplastics, quality encompasses everything across all aspects of production, from customer service, to design and manufacture of our premium grade medical plastics.

A series of Quality Systems and Accreditations form the foundations of Orthoplastics success. Using the requirements of 21 CFR 820 as a guide, we have gained accreditation to ISO 13485 and ISO 14001.

Employing traceability techniques during the manufacturing of all our medical grade product, allows us to regularly assess product quality. All data is recorded and stored for a minimum of 30 years after the manufacturing processes.

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Posted by Marketing on October 18 2019

9th Annual UHMWPE Conference Update

This time last week we were getting ready to attend the 9th Annual UHMWPE Conference at the historic Union League of Philadelphia. We were also proud sponsors of the event and our Managing Director; Mark Allen had the honour of giving a keynote speech.

Mark spoke about ‘a new novel method for the manufacturing of highly crosslinked UHMWPE using x-ray technology.’ A topic he is passionate about, he spoke of the latest STERIS development of a new method to create high x-rays which allow sterilisation and chemical change in UHMWPE.

With sustainability a hot topic in our industry and across many industries, this sustainable development is deemed the long term solution to Gamma processing using highly radioactive isotopes.

The UHMWPE Conference was a great opportunity for us to learn more about new developments and network with leaders and pioneers in medical grade UHMWPE technology and clinical applications.

View the Keynote Speech

If you weren’t able to attend the conference but would like to view Mark Allen’s keynote speech, please request the presentation by contacting us.


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Posted by Marketing on October 10 2019

Orthoplastics Sponsor 9th Annual UHMWPE Conference

As the world’s leading producers of UHMWPE, Orthoplastics are pleased to announce we will be attending the 9th Annual UHMWPE Conference on the 10th-11th October 2019 at the historic Union League of Philadelphia.

Not only will we be attending the event, but we are also proud to be sponsoring the event as Bronze Sponsors and our very own Managing Director, Mark Allen will be giving a keynote speech.

The conference brings together engineers, scientists, clinicians, and regulators from academia, industry and FDA to present leading-edge research on advancements in medical grade UHMWPE technology and clinical applications.

The focus of the 9th meeting is on:

- Advances in processing, crosslinking, and sterilisation of UHMWPE
- New methods of processing clinical and retrieval studies of highly crosslinked UHMWPE (HXLPE)
- The performance of thin acetabular liners and knee arthroplasty
- UHMWPE articulations with ceramic and PEEK bearing surfaces
- Vitamin E and new antioxidant technologies for UHMWPE
- Drug delivery from HXLPE

Since our investment in 3 brand new, bespoke UHMWPE (ultra-high molecular weight polyethylene) extruders we have increased our manufacturing capacity by 75% to ensure we are in the best possible position to move with orthopaedic developments as well as responding to growing market demands and patient expectations.

Mark Allen, Managing Director at Orthoplastics has been invited to be a keynote speaker at the conference, where he will be talking about ‘a new novel method for the manufacturing of highly crosslinked UHMWPE using x-ray technology.’

Mark explains more about this latest innovation saying: “STERIS have developed a new method to create high energy x-rays which allow sterilisation and chemical change in UHMWPE. This sustainable development is deemed the long term solution to Gamma processing using highly radioactive isotopes.”

We are looking forward to hearing about the latest developments and innovations at the 9th Annual UHMWPE Conference and hope to see you there.

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Posted by Marketing on September 03 2019

Further UK business expansion at Orthoplastics

Orthoplastics is pleased to announce plans for the opening of an additional manufacturing facility in the UK.

A world leader in the development and supply of implantable-grade plastics used within the Orthopaedic sector, this expansion is expected to create around 100 new jobs within the local community in years to come.

Official opening expected in 2020

The new building, set to open in February 2020, will enable Orthoplastics to further increase its market capabilities with over £5 million of investment annually. This is a significant move for the business in a rapidly advancing and innovative market and one that is fully supported by US parent company, Viant Inc.


Orthoplastics Facility Expansion 2020



The location of the new facility will be at the Futures Business Park Development in Rossendale (UK). It will fast become a centre of excellence for the business and a launch pad for its extensive global growth plans, designed to ensure Orthoplastics becomes world-leader in polymeric solutions.

Mark Allen, Managing Director, Orthoplastics said: “This significant investment underlines our belief that there is huge potential for innovation and growth within the Orthopaedic sector.  It is also the next step towards achieving our ambition of pioneering improved patient outcomes and the longevity of implantable medical devices. Joint replacement procedures such as HIP and knee surgeries are highly successful of course, but we are leading the way in the evolution of new concepts to improve these life changing operations.”  

Part of a global, growth strategy

The long-term UK manufacturing investment being made by Orthoplastics demonstrates its confident business strategy. “If the Orthopaedic sector is to grow and thrive, we must embrace new technologies and materials. Our vision and ambition for superior materials solutions perfectly represents how we are putting this strategy into practice with Viant globally.” said Mark Allen.

Providing customers with greater surety

“Innovation is at the heart of the future of UK manufacturing, and this factory will provide our customers with the confidence in our long-term investments strategy, whilst demonstrating our strategic partnership and commitment.” said Mark Allen.

A clear focus on end-to-end solutions

Alton Shader, CEO at Viant commented: “We focus on providing end-to-end solutions for medical device OEMs. Our extensive materials expertise including metals, combined with our experience in engineering, manufacturing, assembly, packaging and sterilization, allows us to bring our customers' medical technology solutions to market.

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Posted by Marketing on July 01 2019

Advancing Direct Compression Moulding

As we strive to improve patient outcomes through innovation, we are expanding our direct compression moulding capability with the addition of 5 brand new machines during the last quarter of 2019.

This decision is part of a long-term business strategy focused on introducing new and improved manufacturing technologies. We have always been clear that we want Orthoplastics to be known not just as a leading manufacturer and supplier of UHMWPE, but a business that is making recognised contributions to the advancement of the product and its applications across the world.

Our investment in equipment, technology and in-house capabilities is part of our bigger vision to be at the forefront of setting standards and making new breakthroughs when it comes to manufacturing and designing materials for wide-ranging orthopaedic applications.

Orthoplastics ultimate aim is to be the best it can be when it comes to innovative UHMWPE design and manufacturing techniques, and to ensure that its materials and processes support the manufacture of Orthopaedic limbs and components that can improve the quality of lives for patients through extended product life span, quality, strength etc.

We can create components with a high gloss finish

Although Direct Compression Moulding is a known to be a relatively expensive method of sintering the polymer, it produces components with a high gloss finish. Orthoplastics has focused on advancing this method of manufacturing UHMWPE to ensure that components produced this way are optimised. It has also pioneered the development of an ‘insert moulding’ process, which allows UHMWPE to be moulded onto or into another steel, titanium or ceramic part.

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Posted by HR on June 03 2019

Stuart Green retires after 38 years

Here at Orthoplastics we believe that our staff are the backbone of our business and pivotal to our ongoing growth and success.

It’s with sadness, therefore, that we had to say “goodbye” to Stuart Green, Business Development Director, who officially retired on 29th May after 38 years of loyal service.

Whilst working for Orthoplastics, Stuart has held several senior positions. His knowledge of Orthopaedic plastics, different industries and the latest manufacturing techniques and equipment is unquestionable. As an individual he was highly respected across the medical world. 

A key player in the development of our business

Over the years, Stuart has played a big part in the development and growth of our business and we all wish both him and his family well for the future wherever life takes them.

Managing Director, Mark Allen said, “Good luck Stuart. We’ll particularly miss your drive and dedication. Our staff, directors and customers are sad to see you go. I firmly believe that your input spanning more than 3 Decades has helped us to become a world leader in implantable plastics manufacturing and a key player across the medical sector.“

We want to hear from ambitious, talented individuals that want to kick-start their career

Are you interested in joining a progressive, motivated and ambitious team of people that want to pursue an amazing career in a technical environment?

If you think you have what it takes, we’d like to hear from you. Visit our careers page for details of the sorts of jobs we can offer and how you can submit your CV through our skills hub.

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Posted by Marketing on January 09 2019

A significant component cell expansion

Over the past 12 months Orthoplastics has invested in excess of $4M dollars in a massive expansion to its CNC machining capability.

With the addition of 17 five axis milling centres and 10 lathes, Orthoplastics now has a world-leading component manufacturing cell with 45 state of the art machining centres.

By choice Orthoplastics machining capabilities relate only to plastics, both implant and instrument grade, where we can offer the latest CNC machining centres and lathes. It’s important, therefore, that we keep up-to-date with the latest equipment developments and have the manufacturing capacity to work at optimal levels.

Our investment in new machinery and technology is continuous so we maintain a plant list so customers can appreciate the true extent of our capabilities. Supporting the company’s machinery are Mitutoyo CMM’s and various surface treatments, which are engineered to exceed customer specifications.

We’re so confident in our skilled workforce and industry-leading infrastructure that we believe we can provide high quality components quicker and more cost effectively than any competitor.

Mark Allen, Managing Director, said, “We take great pride in what we do and are committed to providing our customers with a broad range of specialist services. We can only do that if we have the people, technology and equipment in place to respond their requirements. Our ongoing investment programme is extensive and designed to keep us at the heart of our industry in terms of producing UHMWPE implantable materials of a world-leading standard.”

Do you want to find out more about our capabilities? Contact us and send our technical team your questions and we’ll enlighten you.

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Posted by Marketing on December 12 2018

We’ve increased our UHMWPE manufacturing capacity

Orthoplastics has recently invested in 3 brand new, bespoke UHMWPE (ultra-high molecular weight polyethylene) extruders.

This latest technology significantly increases our manufacturing capacity by 75% ensuring we are in the best possible position to move with orthopaedic developments as well as responding to growing market demands and patient expectations.

Orthoplastics operates a series of high performance ram-extruders. Each has a capacity of 30/tonnes of UHMWPE rods and screw extruders of a 50/tonne capacity.

A primary bearing material for wide-ranging Orthopaedic applications

UHMWPE’s high abrasion resistance and toughness makes it an exceptionally attractive solution for orthopaedic applications due to the many complexities of wear.
Orthoplastics manufacture UHMWPE from Celanese GUR® 1020, 1050 and 1020-E polymer via two distinct processes: (1) ram extrusion, which produces a rod shaped product and (2) compression moulding, resulting in a large sheet of product.

“We are committed to raising standards through investment – the recent addition to our plant of 3 new ram extruders is a part of bigger plan”

We believe our manufacturing systems and equipment are the most advanced and specialised in our industry at the present time. That gives us the confidence to take on even the most demanding of projects knowing that our people, processes and technology are up to the job.

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Posted by Marketing on September 12 2018

3D printing is the future and we’re leading the way!

Orthoplastics is pleased to add 3D printing to its in-house manufacturing capabilities.

The new Stratasys OBJET 30 machine has the ability to instantly produce design prototypes and fixtures and is very much a new operational tool for modern manufacturing environments.

This recent acquisition has made our intricate design processes and modelling much sharper, quicker and accurate and underpins our core ability to respond to our customers’ complex requirements covering a broad spectrum of orthopaedic designs and applications.

A big performance machine with an amazingly small footprint!

Our decision to invest in the Stratasys OBJET 30 machine was deliberate given it combines the accuracy and versatility of a high-end rapid prototyping machine with the small footprint of a desktop 3D printer.

Orthoplastics comments, “Now that we have a 3D printing capacity, we have the power and tools to create realistic models with specialised properties quickly, efficiently and easily – and all of this in-house to exacting specifications.”

We can create highly realistic 3D models using the latest print technology

“With its astonishingly realistic aesthetics and ability to deliver special properties such as transparency, flexibility and even biocompatibility, we think it represents the future of high performance design in the field of UHMWPE orthopaedic design across the medical world.”

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Posted by Marketing on February 21 2018

Achieved compliance to ISO 13485 – 2016 Standard

Quality flows through our business and is hugely important to the products, services and support that we give to our customers.

It’s with pleasure, therefore, that we can confirm that have now transitioned to the latest version of ISO 13485:2016.

This has required us to adapt our already robust quality management system and procedures to include a more specific focus on risk management, not only within quality related activities, but areas which feed into the quality management system, such as training and supplier control.

Delivering the highest quality products, consistent with our ethos and overriding medical industry requirements

Orthoplastics ISO 13485 re-certification audit is scheduled for the summer, 2019 and we feel confident that we are ready for this.

Continued compliance to the standard will ensure we can deliver the highest quality products and services to our customers.

Through effective management and maintenance of ISO 13285 across our business, our customers can trust Orthoplastics to be a safe supplier to the medical device industry.

“We remain committed to our customers and take nothing for granted”

We are not complacent about this trust and confidence in our abilities and take nothing for granted. Our team is always looking for ways of ensuring we can move on and provide improved levels of service and product performance.

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Posted by Marketing on September 15 2017

Advanced Level Apprenticeships

We are pleased to announce that two of our advanced apprentices have graduated with flying colours.

Our congratulations go out to Jake Lord and Timmy Mardy who have now completed their Advanced Level Apprenticeships with us in Engineering Manufacture (Mechanical Manufacturing Engineering) in the Science, Engineering and Manufacture Technologies.

Encouraging our staff to go far

As a business we are committed to encouraging all of our employees to expand their qualifications, and to learn about the latest engineering sciences and advanced manufacturing technologies, to help keep us at the forefront of creating and maintaining standards in our emerging marketplace.



Modern apprenticeships like those our staff have recently completed help us to strengthen our skills infrastructure so that we can compete in the modern world, hence we will continue to encourage schemes of this nature.

In addition to studying at college, both Timmy and Jake have now gained valuable on-the-job experience in their chosen professions as CNC Turner and CNC Miller, respectively.

“We would like to extend our thanks to both apprentices and to congratulate them on their recent results. On behalf of the directors and staff at Orthoplastics, we wish them every success for the future.” (Bernadette Dabbs, Sales and Marketing Director)

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Posted by Marketing on September 15 2017

Michael Ulanowicz joins the team

Michael Ulanowicz joins the team as Regional Director of Business Development, in USA.

As part of our continued investment in people and customer service systems, I am pleased to announce that Michael Ulanowicz has now joined our team as Regional Director of Business Development (USA), for MedPlast UK.

This new appointment is a sure sign of our commitment to giving our existing customers more, but will also allow us to develop valued global relationships with new businesses and organisations.

Michael will be managing one or more of our strategic healthcare contracts, and challenged with developing lasting partnerships with potential and existing Orthoplastics customers. He will also be responsible for planning, directing and coordinating programs, involving direct contact and negotiations with many of our key accounts.

As and when necessary, Michael will provide engineering support to help promote and grow wider business development opportunities.

With over 26 years experience in plastic manufacturing processes, Michael is well respected across our industry assisting customers on product realization. This has included materials, design for manufacturing and cost reduction. He has specific insight of working with purchasing, quality and engineering departments in numerous orthopedic, dental and cardiovascular companies.

Michael will report directly to Mark Allen, Managing Director of Orthoplastics. “I’m delighted Michael is now part of our valued team, and I’m sure you’ll join me in wishing him every success.”

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Posted by Marketing on April 25 2017

The importance of our FDA Company Registration

In April 2017, Orthoplastics Ltd became an FDA registered organisation. But why is this important to our business and customers?

Being FDA registered means Orthoplastics comply with the practices of 21 CFR: part 820, which is the code of federal regulations for quality systems relating to medical devices.

A key difference between this and our standard quality management registration is non-compliance to 21 CFR: part 820, which breaks US Law and Regulations.

We have many US-based customers and need the surety that we can meet US market standards and expectations

As a high percentage of our customers are US-based, compliance is paramount for ensuring safe delivery of goods into the US medical device market.

Orthoplastics can provide assistance with FDA product registration as a contract manufacturer within the UK, and our quality team is on hand to provide regulatory and compliance support relating to any new or ongoing applications.

Supporting customers, wherever they are in the world

Mark Allen, Managing Director, said, “We are exceptionally focused on quality as a business. We understand that medical device specifications and products must be consistently delivered to the highest standard. Our various quality registrations prove that we are capable of achieving this and fulfilling the requirements of our customers, wherever they are in the world.”

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Posted by Marketing on February 14 2017

Orthoplastics passes safety audit with flying colours

Orthoplastics believe that every business has a responsibility to ensure they maintain the highest possible standards of health and safety management at all times.

That’s why we’re exceptionally pleased to confirm that we scored highly in a recent safety audit to OHSAS 18001.

OHSAS 18001 is the International Occupational Health and Safety Management Standard. It provides a framework for the effective management of OH&S, including all aspects of risk management and legal compliance. The Standard addresses occupational health and safety, rather than specific product safety matters.

Our Compliance and Regulatory Leader , Rebecca Field, said: “There are over 90,000 OHSAS 18001 certified organisations across 127 different countries. While we are just one of those, it underpins our belief that all successful and responsible businesses need to adopt best practices when managing the safety of the people that work for them.”

Rebecca added: “In our recent audit, we achieved a pass rate of 80% (to OHSAS 18001) which we are justifiably proud of.

What benefits has this brought to Orthoplastics?

Apart from our obvious ability to identify hazards and implement preventative controls, it has improved our productivity and general in-house safety culture, it has assisted with pre-qualification processes for our customers, and it has challenged us to be looking for new and better ways of addressing health and safety issues throughout our business.

Our certification to OHSAS 18001 effectively means that we have a clear management structure with defined authority and responsibilities in place, defined objectives for improvement with measurable results, and a structured approach to risk assessment.

The fact that an independent auditor has visited our site, and thoroughly checked all of our processes and safety management procedures, is a clear indicator to the people that we employ, supply and work with, that we uphold the most stringent and traceable systems possible. It’s also a sign of how important health and safety systems are to our business as a whole.

Want to know more about our health and safety management certifications and commitment? Give us a call.

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Posted by Marketing on January 09 2017

A change in ownership for Orthoplastics

A change in ownership for Orthoplastics

It gives us great pleasure to announce that as of January 2017, Orthoplastics (Medplast Group) has been acquired by Water Street Healthcare Partners and JLL Partners.

Both Water Street and JLL are highly respected investment firms with specialist expertise of the healthcare industry. Each business has many years of medical device experience and has committed significant resources to invest in the Company’s future.

Business as usual

While the new ownership will not affect the day to day running or operations of Orthoplastics, it will mean that we have the necessary finance, expertise and advice in place to guide us into the future and ensure that we continue to keep abreast of market demands, technology advances and legalities in the field of orthopaedic UHMWPE innovation.

It’s still the same Orthoplastics

Chris Turner, Quality Manager, said: “Nothing has changed in terms of what we do, or how we do it. It is very much business as usual for us.”

He goes on: “It’s important at this time, that we reassure all of our existing contacts and customers so that they understand there will be no changes to our management structure. Likewise, we will continue to supply the same products and quality services associated with our name, on which we have built our industry reputation and standing.

So as 2017 starts it seems that, while the ownership of Orthoplastics has changed, its future success and growth in the orthopaedic UHMWPE industry, is even more secure.

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Posted by Marketing on July 19 2016

More innovation from Orthoplastics

As a world-class leader in the development, supply and manufacture of the highest grade, UHMWPE implantable plastics, we think it’s exceptionally important to push the traditional design limits for orthopaedic components.

Orthoplastics’ investment in Direct Compression Moulding has created exciting opportunities for producing innovative, superior performance products

Direct Compression Moulding

Whilst Direct Compression Moulding has been around since the 1990s, the latest generation of metal 3D printing technology has created new potential for product design. Using Direct Compression Moulding to sinter polymers, Orthoplastics can create products with a high gloss finish, which cannot currently be produced….pushing the design envelope for orthopaedic components.

Investment and innovation are vital


Our investment in Direct Compression Moulding means we now have a unique over moulding capability that produces Mono block components with a high gloss, moulded surface. Given each component is individually moulded, we can control all aspects of pressure, temperature and time, during critical consolidation. This ensures that the finished product’s gloss finish and tolerances are far superior in comparison to machined UHMWPE components.

“It’s important to our business to be at the forefront of developing these specialist parts of our organisation so that we can respond to growing customer and industry expectations. With Direct Compression Moulding, each orthopaedic implant is moulded individually. This allows us to produce a component with a highly polished surface, by removing machining surface definition present on the articulated surface of conventionally machined products. It’s a real breakthrough.”

Mark Allen – Managing Director

This alternative way of producing implant components is being heralded as an important development. It further underlines Orthoplastics’ global commitment to maintaining and setting new standards for high-grade UHMWPE components.

New online presence


Read about our Direct Compression Moulding capabilities on our new dedicated website at www.directcompressionmoulding.com

This explains the capability we now have and about our wider research and development, laboratory and testing services.

Orthoplastics is a Medplast company – science making a material difference.

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Posted by Oliver on June 24 2016

Neil Anderton fronts development of new implant manufacturing techniques and processing technologies

Implant engineering techniques and manufacturing processes have been through many stages of development over the years.

Neil Anderton, Technical Manager at Orthoplastics, is at the forefront of introducing the market to the latest technologies and advanced, additive manufacturing processes. These are designed to push the boundaries of what is possible in terms of developing high-quality, patient-specific implant solutions.

“Far too many businesses still don’t recognise the incredible potential that additive manufacturing and 3D printing hold”, said Neil. “There is definitely comfort in using more traditional equipment such as CNC technology. Whilst there have been some breakthroughs in CNC tooling and machine software capabilities, this has been limited.”

Neil believes that CNC machines combined with other equipment, such as lasers for cutting, welding or etching, are the way forward. For example, five-axis machining centres can use data from medical scans to create a broader range of patient-specific implant components, especially for skeletal requirements such as the bone, jaw or skull.

A patient-specific approach

To meet challenging OEM requests for patient-specific implant components, Orthoplastics has created a New Products Innovation Group to explore different sciences, control technologies and manufacturing techniques.

In addition to developing custom devices, there are unique composite device constructions that pose real challenges in respect of component fixation and the need for production controls to an exceptionally high tolerance. “We have invested in innovative fixation techniques and specification-controlled environments within our plant, to respond to customer requirements.”

Neil goes on: “Although industry experts generally believe that additive manufacturing will be the death of traditional machining”, I don’t agree.”

Working alongside a leading implant manufacturer, Othoplastics has used net shape and additive manufacturing to produce a manufactured component with tolerances of 0.01 inches, and machined the final tolerances of 0.001 inches required. This involved sophisticated work holdings and machine probing, along with conventional multi-axis machining.

“All of this clearly demonstrates what innovative approaches can achieve in the OEM market”, said Neil.

“Orthoplastics remains committed to this development work and to spearheading different approaches and cutting-edge advancements in processing technologies.”

To read the ODT publication article in full please click here.

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Posted by Oliver on April 20 2016

Laboratory testing – Orthoplastics lead the way

Without proper testing, validation and certification, new orthopaedic implant products cannot succeed.

Given advancements in technology and increasing regulatory requirements, the need for professional testing, quality management and control during each stage of the production process, has never been more important.

It is widely accepted that compliance, accreditation and associated timelines can be long and expensive when introducing new or improved products. That’s why it’s important to work with a global partner like Orthoplastics that has the appropriate expertise, knowledge and in-house laboratory test facilities. By working with an experienced business, development time (and costs) will be reduced and products will reach the market much quicker.

Investment in technology is key

Orthoplastics is a respected, global expert in the development, production and supply of both implantable grade plastics and biocompatible plastics products for wide-ranging instrument applications. We aim to produce the highest quality, premium grade UHMWPE and work closely with all of our partners to produce new and innovative implant technologies.

Over the years, Orthoplastics has invested time, resources and finance into developing its knowledge of medical plastics, hi-tec manufacturing techniques, test standards and accreditation requirements.

“We have our own fully equipped, laboratory. This is a thriving hub for research and product innovation, ongoing testing and accreditation work. We aim to ensure that each product we manufacture meets the full application, specification and rigorous technical demands required. We believe we provide industry-leading services that are designed and built to support new product developments for our customers.” Neil Anderton – Component Cell Manager

UKAS accredited laboratory

Orthoplastics’ laboratory is UKAS accredited and the majority of projects are carried out in accordance to ISO17025.
Our research and development laboratory has vast experience of testing materials and products manufactured from Ultra High Molecular Weight Polyethylene (UHMWPE), Polyether ether ketone (PEEK) and other polymers, primarily within the medical device sector.

Orthoplastics is a Medplast company – science making a material difference.

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Posted by Marketing on March 16 2016

Orthopaedics AAOS and ORS Florida 2016

Orthoplastics attends the global Orthopaedics AAOS and ORS 2016 meetings in Orlando, Florida
(These meetings are a pivotal launch platform for major OEM’s worldwide).

This year we have seen the further growth of UHMWPE material containing protective antioxidant Vitamin E. As the exposed clinical history for these materials is observed, we continue to secure additional patient benefits, including improved long-term performance.

A huge variety of new porous metal products were exhibited at the show. With advancing 3D printing technology, OEM’s introduction of this and the Monoblock component, are key. We have been instrumental in the design and development of OEM’s worldwide. This novel over-moulding technique, combining UHMWPE with a porous metal, removes the need for complex interlocking features within a design.

Orthoplastics has over 30 years’ experience of providing orthopaedic services. We are a recognised expert in CNC machining and offer the following services:

Design Consultation
Prototyping
Pre-Production Validation
Complex CNC Machining
Full Scale Outsourcing.

Our team of skilled technicians use the latest laboratory equipment to provide a range of testing services. These tasks, which are seen by some as complex, demonstrate our proven technical abilities. Our capability in the manufacturing of moulded products, gives us a competitive edge. Reducing product development costs is at the heart of our business, and our teams are currently working together to achieve this goal.

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Posted by Oliver on February 29 2016

New Orthoplastics’ website goes live

Successfully engaging customers in today’s world requires a Company-wide commitment and recognition that, to stay ahead, a business needs to be constantly reinventing itself.

Orthoplastics, the recognised global leader in UHMWPE machining and manufacturing, with over 30 years’ industry experience to its credit, has recently launched a brand new, browser responsive website for optimal viewing.

“Given the nature of our business and the unique requirements of the medical industry, we have to be continually investing in our machining, testing and development facilities. It’s right, therefore, that our online presence keeps pace with this.

Our new website gives the global market an opportunity to understand our strengths and abilities in the areas of UHMPWE plastics, direct compression moulding, laboratory/test services and component machining. We’re very excited about the launch and see it as a significant step in our development as a business.”
Bernadette Dabbs – Sales & Marketing Manager

Complete solutions for orthopaedic components

Over the past 30 years, Orthoplastics has become a leader in the global orthopaedic implant industry.

UHMWPE

Our business supplies and manufactures premium-grade UHMWPE to leading orthopaedic device manufacturers and is a first choice for a range of modern implants/devices.

Read more here

Direct Compression Moulding

A new generation of metal 3D printing technology has created opportunities for innovative product design. We can now produce Mono block components that have a high gloss, moulded surface. Given the nature of production, we have finite control over the final surface finish and tolerances.

Read more here

Laboratory services

Our world-class technicians, well-equipped laboratory and extensive testing and research/development facilities, ensure that new products meet required application, specification and technical demands of the industry.

Read more here

Component machining

By choice, our machining capabilities relate to plastics, both implant grade and instrument. We have an impressive portfolio of high-end CNC machines and lathes that can meet any manufacturing requirement.

Read more here

Orthoplastics is a Medplast company – science making a material difference.

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Posted by Marketing on February 01 2016

Precision, component machining

Taking new orthopaedic products to market can be a difficult and costly process. The medical industry is tightly regulated and controlled and, therefore, complex to access. Unfortunately many great concepts don’t get past the initial development stage.

The need for quality orthopaedic implant products has grown in recent years and the market is becoming increasingly competitive. With doctors, surgeons, consultants and patients demanding better and more robust treatments, there is now a huge demand for affordable implant innovation.

Professional machining

When developing a product for market, it makes sense to work with a professional machining partner that can provide hands-on help, advice and support, from initial planning and tooling through to materials handling and full-blown production and testing. This will ensure that your investment is secure and costs are controlled.

It takes industry experience, investment in cutting edge equipment and technical insight to produce precision manufactured, orthopaedic products that meet the necessary production, compliance and accreditation requirements set by governing bodies.

Turning concepts into reality

Orthoplastics is a respected, global leader in UHMWPE machining and manufacturing, with over 30 years’ industry experience. We excel in producing the highest grade UHMWPE (Orthopaedic Ultra High Molecular Weight Polyethylene) and work with all of our partners to turn innovative concepts into reality.


Experts in milling, turning, grinding and drilling

By choice, our general machining capabilities relate to plastics, both implant grade and instrument - our CNC machining centres and lathes can respond to any manufacturing requirement.

Alongside our CNC machines, we offer various surface treatments to meet and often exceed customer specifications.

Our component machining services are just part of the story. We provide full consultation, design and engineering and research/development support, as well as rigorous in-house laboratory testing to recognised quality standards.

Over the years our business has been instrumental in producing and testing many new and pioneering orthopaedic implant products that have had a profound effect on patients’ lives.

Our new website is live

Visit our new component machining website at: www.orthoplasticsmachining.com to find out about our 30 years’ experience in the orthopaedic implant industry. This site outlines our component machining strengths and is part of our wider strategy to reinforce Orthoplastics as a world-class leader in UHMWPE machining and manufacturing.

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Posted by Marketing on January 06 2016

Investment In Quality

Quality is absolutely crucial to our business. Over the years, we have heavily invested in resources and equipment to provide our customers with everything required for regulatory compliance on a global scale.

3rd Mitutoyo scanning heading CMM, along with statistical monitoring software, enable a live data capability analysis. These take traditional inspection and processing to a new level of compliance and control.

Validation and compliance team expansion

As our business grows so must quality. With our recent investments and expansion, we again demonstrate the cost of quality can never be too high, particularly when lives are dependant on our products, services and materials.

The needs of the medical sector are constantly changing to cope with advances in medical science. Orthoplastics continues to respond and to nurture the confidence of its employees. The standards set by the market are increasingly high, but the value added services we provide are designed to match that standard. Most recently, our research centre has realised that their core potential lies in UHMWPE materials hence it is focusing their talents in this area.

Responding to the demands of modern medical science requires a fully integrated approach. At our Orthoplastics facility in Manchester there is evidence of great innovation. This is where our experienced team come together to develop a range of products that are highly efficient and capable.

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Posted by Marketing on December 07 2015

Expanding Implant Manufacturing Cell

We have been excited by the rapid expansion of our polymer implant-manufacturing cell. The introduction of five state-of-the-art axis milling machines has highlighted our commitment to adopting modern machining practices, leading to shorter lead times and highly competitive pricing.

Component machining is an effective way of converting orthopaedic component concepts into today’s reality. Being world leaders in implantable plastic manufacturing and component machining, Orthoplastics is considered among the leading experts in CNC machining. Our environment-friendly machines and in-house capacity, allow us to provide a full range of machining services.

Some of the services we provide include:

- One-off prototyping
- Pre-production validation runs
- Outsourcing service.

We provide a bespoke design service so we can respond to each customer’s requirement. Rest assured, each and every investment that we make is for our customers and to create even higher standards of performance.

Orthoplastics is committed to providing exclusive product solutions, serving the needs of SMEs. Working with us, gives SMEs a real opportunity to overcome technological, regulatory and financial constraints that can stifle their success. We do this by using our in-house talent and expertise to help with complicated legal requirements such as accreditation, compliance, affiliation navigation processes etc.

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Posted by Marketing on November 11 2015

UHMWPE Conference Philadelphia 2015

Orthoplastics was pleased to make a presentation at the recent 7th UHMWPE conference in Philadelphia. This brought together experts from various fields such as engineers, scientists and clinicians from academia and industry. It was an opportunity to hear about the latest research, advancements and developments in medical grade UHMWPE technology and clinical applications.

The results of various clinical and retrieval studies of immensely correlated UHMWPE (HXLPE) work was presented to the panellists. Special mention was made about thin acetabular liners and knee arthroplasty performance. In addition to this, the following was also discussed:

- Long terms consequences of 1st generation HXPLEs

- Risks and benefits associated with HXPLE

- A detailed comparison of short term results of anti-oxidant additive stabilized HXLPE and the 1st generation HXLPE

- Thermal processing effects and advancements for HXPLE

- Fibre application advancement of UHMWPE for surgical applications

The organisers accepted three technical research papers and selected two for podium presentations.

The use of high powered x-ray for the manufacture of highly cross-linked UHMWPE, the improved dose uniformity when compared to alternatives such as Gamma and e-Beam

The physical/mechanical performance of highly cross-linked UHMWPE processed using the new novel X-Ray facility.

The use of highly modified UHMWPE in spinal applications, when compared to the costly modern day spinal biomaterials.

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Posted by Marketing on September 14 2015

Major Contract Win

In October 2015, Orthoplastics secured a major machining contract win with one of the World's leading orthopeadic device manufacturers. This prestigous and exciting development has resulted in the acquisition of three new 5 axis CNC machines that will increase the overall capacity within the machining department.

As a world leader in implantable plastic manufacturing and component machining Orthoplastics have the expertise to navigate customers through the complexities of production, compliance and accreditation, getting medical component products to market quickly and saving customers valuable time and money.

If you would like to know more about these unique services then click here

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Posted by Marketing on July 01 2015

Orthoplastics China Expansion

The expansion of Orthoplastics China has taken place over many years. Kelvin Wu has represented us in this territory and has been instrumental in securing our success. As part of our planned growth in this region and within Asia generally, Mr Wu has now been appointed as our official representative for China, Japan and Korea.

In addition to Kelvin’s new geographic responsibilities, we have expanded the role of Bernadette Dabbs to include sales, marketing and account management, in addition to her already successful leadership of our customer services team.

Orthoplastics is solely dedicated to the medical sector around the globe. There are no geographic boundaries when it comes to helping our customers. This is part of the strategic growth and expansion strategy.

We firmly believe that quality standards are maintained throughout the world because of our accreditation to ISO 9001, ISO 13485 and ISO 14001. The supply chain mechanism and distribution network of Orthoplastics, ensures that products can be transported to each corner of the globe, in full compliance with relevant security and safety standards. The export quality of our products is unrivalled - we are considered to be the market leaders in providing specialist guidance and support to customers in the medical sector.

The growth strategy of Orthoplastics is evidence of great leadership and rigorous quality assured products and services, ranging from cross-linked UHMWPE and Vitamin E UHMWPE, component machining, to direct compression moulding and laboratory services.

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Posted by Marketing on April 01 2015

World Class Test Laboratory

We adopt the most stringent of orthopaedic test methods and global standards. Over the years, we have developed a world-class testing facility, compliant with ISO 17025. To further expand this capacity and requirements from OEM customers, we are now offering long-term device package testing.

The validation and characterisation of polyethylene often crosses the boundaries into packaging, especially when it comes to long-term shelf stability.

Our laboratory is fully equipped with:

Nicolet FTIR
Netzsch DSC
Cambridge Polymer Group Swell Ratio Tester SRT-1
Multi-axis Tensile Test
Oxygen bomb.

Our lab is equipped for multi-tasking hence we are able to deal with a number of jobs consecutively. With our extensive range of testing equipment, ultra-high molecular weight polyethylene and other polymers have become key products.

We have invested in the latest technological equipment so that we can innovate different ideas and products. We conduct related research and development in our laboratory so that we can respond to market trends and are more able to serve our customers. The whole concept of the implantable industry is founded on the rigorous testing and manufacturing of plastics products in the laboratory, hence we are extremely proud of our achievements.

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