Dufaylite’s partnership with the MTC: A valuable investment in efficiency
At Dufaylite, innovation is at the heart of everything we do. Transforming the manufacturing sector on a broader scale is not just a byproduct of our own progress; it’s integral to the way we operate and a significant part of our overarching mission.
The Dufaylite MTC partnership reflects this commitment, combining our passion for sustainable paper honeycomb solutions with the MTC’s expertise in advanced manufacturing innovation. Learn more about our wider approach to sustainability on our Sustainability page.
We’ve been bringing recycled paper honeycomb solutions to the market since 1955, and during this time, we’ve learned that the only thing that’s constant is change. We understand that we need to adapt to stay ahead, and that this often means investing in external advice.
Back in 2018, we decided to assess our workplace practices, identify inefficiencies, and find the right consultancy partner to help us improve productivity and performance.
About the MTC
The Manufacturing Technology Centre (MTC) is a leading UK-based research and technology organisation that specialises in helping manufacturing businesses solve complex challenges through cutting-edge technology and innovation.
How the MTC supports manufacturing businesses
To date, the MTC has delivered over 9,000 projects, helping its clients transform their processes, develop new products, optimise their supply chains, upskill their teams, scale their ventures, and explore sustainable manufacturing and net-zero practices in line with shifting attitudes and tightening legislation.
Our commitment to sustainability extends beyond our collaboration with the MTC. We also work closely with Carbon Quota to measure and reduce our carbon footprint, ensuring that every improvement we make is backed by real evidence and contributes to a more sustainable future.
Where it all began
Initially introduced to the MTC via a local networking event, we were intrigued to learn more about their approach and capabilities, so we decided to visit the team’s HQ in Coventry. We were impressed by their operations and could see they were pushing boundaries with their work.
Following several conversations, we instructed the MTC to deliver and implement a bespoke product improvement programme at Dufaylite, aiming to increase efficiency and output from our St Neots factory, particularly on the paper honeycomb lamination line.
This marked the beginning of the Dufaylite MTC partnership – a collaboration aimed at driving measurable improvements in efficiency, innovation, and sustainability.
The challenge: optimising our manufacturing strategy
At this point, we recognised that demand for our products would grow exponentially, and we acknowledged the need to transform our manufacturing processes to meet the expectations of our existing and future clients more effectively.
We wanted to offer truly sustainable products without excessively long lead times – and, first and foremost, we were looking to the MTC to help us achieve this by addressing the bottleneck in our lamination line production processes. The goal here was to ensure that every product came off the line dry, cut to size, and required minimal rework.
The solution: a bespoke product improvement programme
To develop an effective plan, the MTC needed to understand our business in its entirety, so they set about learning about our products, outlining our processes, and, just as crucially, collaborating with our team.
Key representatives completed a comprehensive line walk, after which they recommended creating a value stream map. This enabled the MTC team to outline all our current manufacturing processes and examine ways to improve our mechanical and operational processes.
They invested valuable time in understanding our production process and how it all comes together. They worked closely with our team, discussing at great length what needed to change and how our staff could be part of this transformation. This collaborative approach increased employee engagement and buy-in, ensuring everyone played a role in the success of the project.
The MTC eventually helped us source, prototype, test, and introduce new technology that improved drying efficiencies on our lamination line, enabling us to speed up manufacturing in this area without compromising product quality.
The consultants also assisted us with financing the project by introducing us to the Innovate UK Reach SME grant scheme and other funding opportunities.
The result: a 400% increase in output
The statistics speak for themselves. Since completing this initial project with the MTC, we have experienced a 400% increase in output on our lamination line alone.
Additionally, prior to seeking the MTC’s advice, we would typically produce around 300,000 metres of paper honeycomb product per year; now we have comfortably exceeded one million metres.
The MTC also helped us optimise the factory floor for improved workflow. Before engaging them, our management team were concerned that we would need to relocate our facilities to meet growth targets – but thankfully, everything we need is right here. We just needed to be shown how to optimise our current setup.
The Dufaylite MTC partnership has become a cornerstone of our operational success — proving that collaboration and technology can drive real, measurable transformation in manufacturing.
Impressed by the MTC’s breadth of knowledge and diligent approach, we have since partnered with them on a range of other projects that have improved our processes and enhanced productivity.
Insight from Ashley Moscrop, Managing Director at Dufaylite
What sets them apart from other consultants is their ability to step away once their work is complete. They’re never aiming to become an integral part of your process and your business; they simply give you the knowledge and the tools to get the job done, then, once the improvements are in place, allow you to go away and continually work on things. And the best part is, if you need future help and guidance, they’re always willing to jump back in.
What’s next for Dufaylite and the MTC?
We will continue to partner with the MTC as we work towards entering new markets and doubling the size of our organisation over the next few years. We look forward to exploring new solutions under their guidance, including automation systems and AI-driven technology.
The Dufaylite MTC partnership continues to evolve, driving innovation, efficiency, and sustainable manufacturing as we look to the future of paper honeycomb production. To discover more about our long-term sustainability commitments, visit our Sustainability page.
→ Learn more about the Manufacturing Technology Centre and how they’re transforming UK industry at the-mtc.org.
Placing our trust in the MTC has been hugely beneficial for Dufaylite. Their enthusiasm for our work and their drive to better our business have been fantastic, and collaborating with them continues to be a pleasure.
