Giving our customers a competitive edge through smart design
Our process starts with listening to your specific challenges and needs. Our expert team then explores and develops a fit-for-purpose response, be it designing new products, developing new manufacturing techniques that improve efficiency, quality or reduce cost, or even boosting sustainability or reducing impact of pre-existing products through material innovation.
We treat your commercially sensitive information with respect. As our Design, R&D, Engineering and Manufacturing teams are all inhouse, it means your information will not be sent out to outside contractors and therefore keeps a tighter control on your information.
This proven process has been refined over our 50 years to ensure you have no issues further down the manufacturing line, offering protection and transparency.
Benefits of working with EPL
We love to see our customers succeed
We want to develop a true partnership and you will be involved with the development process all the way.
50 years of experience
EPL has over 50 years of experience developing components for our customers.
100% New Zealand owned
EPL is 100% New Zealand privately owned company with our head office & manufacturing facility located in Christchurch.
Inhouse design team
We are proud to have our own inhouse design team located at our Christchurch head office.
Inhouse engineering team
We are also proud of our inhouse engineering team who not only make the dies for your profiles, they also make the machines that are used in the manufacture of your products.
Proven technology
We have 50 years experience of developing profiles, our technology is proven.
Prototyping
We are able to create prototypes of your design to help with evaluation.
We treat your commercially sensitive information with respect
As our Design, R&D, Engineering and Manufacturing teams are all inhouse, it means your information will not be sent out to outside contractors and therefore keeps a tighter control on your information.
The custom development process
Elevate your product vision with EPL’s bespoke five-step innovation engine , melding our decades strong, in-house design expertise with industry-leading development milestones to accelerate time-to-market, optimise costs, and drive commercial triumph.
Initial Scoping & Consultation
Our journey begins with a deep dive into your unique business needs. We schedule an in-depth consultation to understand your vision, challenges, and specific requirements. This initial stage is crucial for aligning our technical expertise with your strategic objectives. We'll explore your goals, target audience, and desired outcomes to create a comprehensive project blueprint.
Technical Specification
Our R&D team takes the gathered information and begins to crystallize the concept into precise technical specifications. We carefully select optimal polymer formulations, determine exact extrusion process parameters, and develop a comprehensive understanding of the project's technical requirements. This phase involves creating detailed technical drawings, calculating material consumption, and projecting potential manufacturing challenges.
Quotation
The quotation process provides a transparent and detailed financial and technical proposal that gives you a complete picture of the project's scope and investment. This transparent approach ensures that you have all the information needed to make an informed decision, with no hidden costs or unexpected complications
Design & Development
The design and development phase is where conceptual requirements are transformed into manufactured reality. Our team employs advanced computational techniques, including CAD modeling, computational fluid dynamics simulation, and thermal analysis. We create precise die designs, validate material flow, and optimize every aspect of the extrusion process. This stage involves the fabrication of prototype dies, initial sample production, and comprehensive material testing.
Frequently asked questions about our custom development process
-
What is the advantage of Polymer Extrusion?
Extrusion molding offers several compelling benefits compared to other plastic manufacturing processes, making it an ideal choice for continuous-profile products:
Continuous, High-Volume Production
Extrusion is inherently a continuous process, capable of running 24/7 once set up. This enables extremely high throughput—up to tens of tonnes per hour—while minimizing production stops and changeovers.Low Unit and Tooling Costs
Dies for extrusion are much simpler and less expensive than multi-cavity injection molds. The lower initial investment and rapid amortization through continuous runs translate into a lower cost per part, especially for long production lengths.Material Efficiency and Recyclability
Thermoplastic scrap generated during extrusion (e.g., trim or start-up material) can be immediately re-melted and reused, reducing waste and raw-material costs. This “closed loop” recycling capability also supports sustainability objectives.Post-Extrusion Manipulation
Extrudates leave the die still hot and pliable, allowing secondary operations—such as stretching, embossing, or lamination, to be performed in-line immediately after shaping for additional customization.
Wide Material Compatibility
Extrusion handles most thermoplastics (PVC, PE, PP, PET, ABS, bio-based resins) and thermoplastic elastomers, as well as co-extrusion of multiple layers for barrier or decorative functions, all with minimal changeover time.Consistent Mechanical Properties and Surface Finish
Continuous, uniform processing yields profiles with predictable, homogenous mechanical performance along the entire length. Modern extruders deliver smooth surface finishes that often eliminate the need for post-processing.Rapid Time-to-Market.
With simplified tooling, quick die fabrication and fast process optimization, extrusion projects can advance from design to production significantly faster than complex molding methods—accelerating product launches8.These advantages make extrusion molding the preferred solution for applications requiring long runs of constant-section profiles—such as tubing, rails, gaskets, frames and multi-layer films—delivering cost-effective, efficient and sustainable manufacturing.
-
What types of products can you manufacture?
We manufacture:
- Extrusion profiles.
- Injection molded components.
-
What type of materials can you use?
We manufacture components out of a wide range of materials including bio-based, traditional polymers and silicone.
-
Why is it important to fill in our a development questionnaire?
The development questionnaire is a vital part of our development process. The Design and Engineering team use the information in this to make decision around the formulation of material and the design of the profile. This can have implications on the cost of the component.
-
What is some of the key information we need?
As well as the development questionnaire, other useful information is:
- A drawing of the product with the key critical dimensions listed on it.
- An application of what the product is used in if available.
-
How does EPL Ensures Unwavering Quality
EP's commitment to quality underpins every phase of its custom development process. By integrating rigorous standards, real-time monitoring, and a lifecycle-focused design philosophy, EPL guarantees products meet the highest performance, reliability, and sustainability benchmarks
Learn more about EPL's commitment to Quality
Types of materials we work with
Ready to Transform Your Ideas into Custom Plastic Solutions? Contact EPL Today!
Take the first step toward bringing your bespoke polymer extrusion or injection-molding project to life.
