Designing quality plastic extrusions

Our ability to supply high quantity plastic extrusions starts at the design stage. Designing a product that suits the extrusion process is key when it comes to our ability to constantly supply and manufacture products with critical dimensions. Understanding factors such as the differential cooling ‘the effects of uneven cooling during the extrusion process’ and explaining these to our customers keeps us and our customers at the top of our game.

Shadow graph technology

Whilst we pride ourselves upon our ability to design and manufacture complex plastics extrusions, the quality of a product is very much dependent upon in process quality controls, procedures and checks. Flexible profiles can be very difficult to measure, as part of our manufacturing process we utilise shadow graph technology to enlarge and inspect critical dimensions ensuring the flexible extrusions we supply are of the highest quality.

The extrusion process – adding adhesive tape

Many of our plastic extrusions can be manufactured with one or more lines of adhesive tape being added in line with the extrusion process. Applying the tape as part of the extrusion process avoids the time and cost of adding tape at a later date. Working together PAL Extrusions can offer expertise on plastic extrusion design whilst our adhesive tapes division ‘PAL Adhesive Products’ can offer technical advise on the correct tape for your application.


PAL Group manufacturing facility re-opened on the 20th April 2020

PAL Adhesives continuing to trade and support customer base

To support customers that are able to trade at this difficult time the PAL Group partially re-opened its manufacturing facility on the 20th April 2020, over the coming weeks as more businesses require our services and restrictions are lifted we will extend production in line with demand. Due to Covid-19 related product production our adhesives tapes division has remained partially open and will remain reactive to customer demand.

Activities at this time are based upon those that are essential so our site remains closed to visitors and deliveries unless specifically agreed.  Key staff members will continue to work from home, should your normal contact be unavailable our main contact email addresses are:

We would like to extend a big thank you to all those suppliers and customers helping us through this very difficult time, may we wish all of you a safe and healthy return to normality.

If we can be of service to you please do not hesitate in contacting us.

Simon Lowe

Managing Director









Please be advised that due to the unfolding situation PAL Extrusions will be standing down much of its normal operations at 3.30pm on Friday 27th March 2020. We shall continue to monitor the situation in anticipation of resuming normal services as soon as is possible.


Our facilities are and will continue to be engaged in the manufacture of Covid-19 and other customer critical supplies, some manufacturing will therefore continue with the rest of our operation and staff remaining on standby. Demand will be assessed on a case by case bases so please do not hesitate in contacting us should you require our services.


In line with Government guidelines and to protect our staff, their families and the wider community our offices, despatch and production departments will be closed to visitors and deliveries. Key staff members will be working from home and contactable using the following email addresses:


May we wish all of our customers, suppliers and their families the very best at this difficult time.

FIT @ NEC May 2019

An opportunity to meet PAL Group staff representing our full range of products – PAL Glazing, PAL Extrusions, Geoplas Building Products, PAL Adhesive Tapes and Fensys UPVC Decking, Fencing & Gates. You will find us in Hall 6, Stand K66. The Fit Show is at the NEC and runs 21st to 23rd May 2019. We look forward to seeing to there.

FIT SHOW May 2019

THE PAL GROUP | Geoplas | PAL Extrusions | PAL Glazing | Fensys | PAL Adhesive Tapes. Don’t forget to start making plans to visit us at this year’s FIT SHOW, we will be on hand to talk about the PAL Group’s innovative range of trade products and services. Plastic Extrusion | Roofline Plastics | Bespoke Extruded Building Products | Glazing Seals and Gaskets | Adhesive Tapes | Plastic Decking Products | UPVC Gates and UPVC Fencing. The FIT SHOW runs from 21st to 23rd May at the NEC Birmingham, we do hope you can find time to visit.


BESPOKE CUSTOMER DESIGNED EXTRUDED PROFILES. PAL Extrusions offer design assistance and encourage involvement between the company and clients, from concept to reality, in order to develop a successful profile. Using considerable production expertise and investment in CAD technology and modern plant they are now leading the way in the development of rigid & flexible profiles for a variety of new markets. These include Caravans & Motor homes; Automotive & commercial vehicles, Shop fitting, Kitchens & Partitioning . Continue reading


TOOLING DESIGN AND PRODUCTION FACILLTY – As many manufacturing sectors de-skill and turn to out side sources for technical projects, the PAL Group continues to invest in its state of the art in house extrusion tooling design and production facility. Designing and manufacturing our own tooling allows us to invest that little extra on tool quality, line speed and custom details such as co-extrusion. All of our tools are made to the highest standard and not just to a budget. The Benefits of high product quality, long life tooling and faster production speeds are then enjoyed by us and our customers alike. We take pride in the high quality of the products that we produce making it essential that our plastic extrusion tooling is also of high quality and well designed. Our technical expertise often leaves us without competition where the extra time taken to develop and produce high specification tooling puts us in the position of being market innovators and leaders.


TOURING CARAVAN PROFILES PLASTIC EXTRUSION DESIGN – Years of experience has taught us to listen to our customers and in doing so we have created many industry leading designs. Designs such as these extruded touring caravan locker profiles, this project needed to combine market leading aesthetic design whilst delivering a weight saving that would allow the caravan manufacturer to add luxuries such as air conditioning into the caravans. The completed design not only for filed the brief but also produced an over all cost down by using less material than its predecessor and time saved on assembly. Rigid PVC, metallic polymers and paper wrap wood grain finishes were all included to produce these market leading extruded profiles.