{"id":56805,"date":"2025-12-22T10:41:51","date_gmt":"2025-12-22T10:41:51","guid":{"rendered":"https:\/\/manufacturing-today.com\/?p=56805"},"modified":"2025-12-22T10:41:53","modified_gmt":"2025-12-22T10:41:53","slug":"royston-lead-combines-decades-of-expertise-with-cutting-edge-technology-to-deliver-safe-sustainable-lead-solutions","status":"publish","type":"post","link":"https:\/\/manufacturing-today.com\/news\/royston-lead-combines-decades-of-expertise-with-cutting-edge-technology-to-deliver-safe-sustainable-lead-solutions\/","title":{"rendered":"Royston\u00a0Lead\u00a0combines decades of\u00a0expertise\u00a0with\u00a0cutting-edge\u00a0technology to deliver safe, sustainable lead solutions\u00a0"},"content":{"rendered":"<p><span data-contrast=\"auto\">With roots going back to the 1920s and formal incorporation in 1946, Royston Lead has evolved from a heavy-steel fabricator into a UK-based specialist manufacturer of engineered lead and lead-alloy products. Now recognized for its commitment to the highest standards of quality, safety, and sustainability, Royston Lead produces more than 50,000 tons of lead every year and has provided innovative lead products to some of the world\u2019s biggest names.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\"><img loading=\"lazy\" decoding=\"async\" class=\"alignleft size-full wp-image-56807\" src=\"https:\/\/manufacturing-today.com\/wp-content\/uploads\/sites\/4\/2025\/12\/Royston-Lead-243-body-image-1.jpg\" alt=\" severely corroded metal bars or a grate submerged in a dirty, possibly oily, liquid\" width=\"425\" height=\"300\" srcset=\"https:\/\/manufacturing-today.com\/wp-content\/uploads\/sites\/4\/2025\/12\/Royston-Lead-243-body-image-1.jpg 425w, https:\/\/manufacturing-today.com\/wp-content\/uploads\/sites\/4\/2025\/12\/Royston-Lead-243-body-image-1-300x212.jpg 300w\" sizes=\"auto, (max-width: 425px) 100vw, 425px\" \/>Delivering both standard and fully bespoke lead solutions, tailored to sector-specific requirements, the organization serves critical sectors worldwide, including nuclear, medical,\u00a0marine\u00a0and offshore, mining,\u00a0construction\u00a0and petrochemical. Today, Royston Lead offers a broad portfolio. Its products support highly demanding and safety-critical applications, from x-ray and radiology shielding in hospitals to ballast for ships as well as critical parts for the nuclear industry.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Now part of International Metal Industries Limited (IMI), a wider group of companies specializing in lead products, Royston Lead is equipped with\u00a0cutting-edge\u00a0technologies and\u00a0a state-of-the-art\u00a0smelting plant in South Wales. The company\u2019s three core strengths are\u00a0centered\u00a0around lead plate, extrusions, anodes, and healthcare, which have been key in\u00a0maintaining\u00a0its dynamic growth and sustained success.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">It\u2019s\u00a0been five years since Manufacturing Today last spoke with the business, so to get a more recent update, in December 2025, we joined Frank Lynch, Commercial Director, to gain insights into how the company has progressed. \u201cAbout 14 months ago we made some changes in senior management, and subsequently focused on our key strengths in rolling, extrusion, anodes and healthcare, rather than being spread too thinly across multiple sectors,\u201d he begins. \u201cWe have also placed a huge emphasis on quality. We have a new Quality Manager who is developing new systems to\u00a0optimize\u00a0our processes. Additionally, our new Health and Safety Manager has put this critical area at the\u00a0center\u00a0of our thinking and ensures that all the safety protocols are followed, from wearing the correct PPE to regular lead blood monitoring.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">\u201cFurthermore, we have revitalized our work with the mining sector,\u201d Frank continues. \u201cThis used to be a huge part of our business, making up around 80 percent of our revenue, but following the pandemic and Russia-Ukraine conflict, the industry declined. While it has been tough, we are seeing a material uplift in the last 12\u00a0months\u00a0especially in Europe.\u201d<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Increasing efficiency has also been on the agenda, and as Frank confirms, a variety of\u00a0new approaches\u00a0have been introduced across the business. \u201cFor example, when\u00a0you\u2019re\u00a0in the lead sector, you need to have a shower and change your clothes when you have a break, and this can quickly add up in terms of hours spent on these tasks. So, we looked at shift patterns and have recently changed from a five to four-day work week to decrease the number of breaks that everybody needs,\u201d Frank details. \u201cThis also gives us a day for maintenance projects.\u201d Further staff improvements include the introduction of clear salary brackets that reflect the addition of extra skills.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">\u201cSince I joined three and a half years ago,\u201d Frank elaborates, \u201cIMI has always been open to investment. If you put together a clear plan of what is needed and what the payoff will be,\u00a0they\u2019ll\u00a0back it.\u201d As a result, Royston Lead has upgraded both technology and equipment. \u201cWe\u2019ve\u00a0brought in new presses, casters, even robot welders; if it makes sense and pays off, IMI is on board.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">\u201cA lot of what we do is still one-off work. Even in mining and healthcare, every project is a variation on a theme, and we still get the occasional completely bespoke<img loading=\"lazy\" decoding=\"async\" class=\"alignright size-full wp-image-56808\" src=\"https:\/\/manufacturing-today.com\/wp-content\/uploads\/sites\/4\/2025\/12\/Royston-lead-243-body-image-2.jpg\" alt=\" the process of machine casting lead sheet, where molten lead flows onto a cooled roller to form a continuous sheet\" width=\"425\" height=\"300\" srcset=\"https:\/\/manufacturing-today.com\/wp-content\/uploads\/sites\/4\/2025\/12\/Royston-lead-243-body-image-2.jpg 425w, https:\/\/manufacturing-today.com\/wp-content\/uploads\/sites\/4\/2025\/12\/Royston-lead-243-body-image-2-300x212.jpg 300w\" sizes=\"auto, (max-width: 425px) 100vw, 425px\" \/> cast or machined part. Wherever possible, we stick to extrusion, cutting and palletizing because it streamlines everything. In terms of major projects, we\u2019ve supplied ballast for ships, and delivered complex cast, machined and assembled components for facilities like CERN and ESS. In healthcare, we\u2019ve completed 234 installations in three years, including full PET and CT suites at Guy\u2019s and the Royal Free, with projects ranging from \u00a32000 to \u00a3500,000.\u201d<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Environmental responsibility plays a huge part in Royston Lead\u2019s operation. \u201cMost of our raw material comes from car batteries,\u201d Frank continues. \u201cIn our processing plants, every\u00a0component\u00a0is reused. Even the plastic casings are broken down for products like washing-powder additives, and other elements are repurposed elsewhere. Just over 99 percent of each battery is recycled, so waste is extremely minimal. Energy efficiency is another big focus across all our sites. On the health and safety side, lead exposure is tightly controlled. And because we\u00a0operate\u00a0near homes, a\u00a0school\u00a0and a park in Barnsley,\u00a0we\u2019re\u00a0especially conscious of our environmental impact. We\u00a0don\u2019t\u00a0just meet regulatory requirements; we exceed them.\u201d<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Looking to the future, Frank shares Royston Lead\u2019s plans to concentrate on its three core growth areas. \u201cThe anode sector is expanding,\u201d Frank explains, \u201cand there\u00a0aren\u2019t\u00a0many manufacturers in Europe, so our decades of experience give us an advantage. We also provide a full recycling loop. Anodes are typically in service for 2-10 years, and when customers return them, going forwards we will be recycling the material and use it to produce new ones.\u00a0It\u2019s\u00a0cost-effective for them and sustainable for us.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">\u201cHealthcare is another area where\u00a0we\u2019ve\u00a0built real momentum. Last year was quiet for major projects, but the pipeline for the next two to three years looks extremely strong, with several large installs on the horizon.\u00a0We\u2019re\u00a0also starting to grow into Europe, working with the Department for Business and Trade to raise our profile. A big part of that is refreshing our website and putting more energy into marketing, which\u00a0we\u2019ve\u00a0admittedly neglected while focusing on delivery.<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">\u201cFinally, extrusions\u00a0remain\u00a0a key pillar. We already supply a lot of extrusion work into Europe and with the new press and billet caster, we can significantly increase our efficiency and capacity. Between anodes, healthcare, and extrusions,\u00a0that\u2019s\u00a0where we see the future growth of the business.\u201d<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><span data-contrast=\"auto\">Customer service will also be a major focus for the business with more office staff and a customer-focused sales team. \u201cOver the past two years, we\u2019ve worked hard to improve communication,\u201d Frank shares. \u201cBeing transparent and keeping customers informed is critical. Quality has also been a key area, with new managers and stricter processes reducing rework and ensuring everything leaving the factory meets\u00a0high standards. Alongside this,\u201d he concludes, \u201cwe\u2019re exploring ways to grow the factory, utilizing available space for future projects, all while maintaining focus on multi-skilled operatives, structured shifts, and continuous improvement across the business.\u201d\u00a0<\/span><span data-ccp-props=\"{}\">\u00a0<\/span><\/p>\n<p><a href=\"http:\/\/www.roystonlead.com\" target=\"_blank\" rel=\"noopener\"><strong>www.roystonlead.com\u00a0<\/strong><\/a><\/p>\n","protected":false},"excerpt":{"rendered":"<p>With roots going back to the 1920s and formal incorporation in 1946, Royston Lead has evolved from a heavy-steel fabricator into a UK-based specialist manufacturer of engineered lead and lead-alloy products.<\/p>\n","protected":false},"author":6,"featured_media":56806,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"content-type":"","footnotes":""},"categories":[670,657],"tags":[3356,4119,4122],"class_list":["post-56805","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-engineering","category-insights","tag-metals","tag-4119","tag-royston-lead"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.0 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Royston\u00a0Lead\u00a0combines decades of\u00a0expertise\u00a0with\u00a0cutting-edge\u00a0technology to deliver safe, sustainable lead solutions\u00a0<\/title>\n<meta name=\"description\" content=\"Royston Lead has evolved from a heavy-steel fabricator into a UK-based specialist manufacturer of engineered lead and lead-alloy products.\" \/>\n<meta name=\"robots\" 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