Rehau UK says it is continuing substantial investments across two key UK sites.

The company’s manufacturing plant in Blaenau Ffestiniog and its recycling centre in Runcorn, Rehau Recycling, are both undergoing major upgrades as part of a wider strategy to increase capacity, improve efficiency and reduce environmental impact.

At Blaenau, Rehau UK is investing £2.5 million in new tooling and equipment over the course of 2026, in line with its continued expansion of its coextrusion capabilities. The site first introduced coextrusion lines in 2018, and now operates seven, with an eighth line expected to be operational by the end of 2026.

Coextrusion technology allows virgin and recycled plastics to be combined, enabling a higher proportion of Rehau high-quality window profiles to incorporate recycled PVC in their core. The proportion of product made using recycled materials has increased year on year and Rehau is targeting 65% by end of 2027 with the help of its new investments.

The Blaenau plant has also benefited from a £1 million solar array installation to help tackle rising energy costs. Further upgrades in the factory include an improved lamination plant, with the focus on shorter changeover times to increase flexibility, as well as the introduction of self-cleaning filtration systems and EV forklift trucks.

Dylan Roberts, production manager at Rehau UK, said:

“We respect that we have a team here with real loyalty to Rehau. Many of our staff have been with us for over 20 years, and that experience is invaluable. These investments are about giving them the best possible environment and equipment to work with. We have always been a people focused site, and that will not change as we continue to grow.”

Staff development has been central to the investment programme. New coextrusion operator roles have been created, with employees travelling to Poland and Germany for specialist training. SMART initiatives on coextrusion lines have also seen technicians undertake development programmes overseas. Increased automation across the site has enabled operators to manage multiple lines simultaneously, increasing efficiency while upskilling the workforce.

At its recycling facility in Runcorn, Rehau UK is executing a five-year strategy to significantly increase processing capacity. The site expanded its output by 21% in 2025-6 and aims to nearly double its tonnes per day processing capabilities by 2028.
To meet this demand, Rehau UK is installing a new heavy duty shredding line, along with specialist material sorting technology, and a metal detection system. Rehau Recycling is also expanding its site footprint and has introduced a new material dryer to support operations. The investment programme is expected to be completed by the end of 2026, with the site expansion finalised by 2028.

Ian Ward, procurement manager at Rehau Recycling, said:

“The upgrades at Runcorn are driven by what is happening at Blaenau. More coextrusion lines mean greater demand for recycled material, and by increasing our internal capacity we can meet that demand without relying on external sources.

“It keeps the supply chain within Rehau’s sphere and supports our wider sustainability goals.”

The upgrades will see Rehau Recycling solidify 38 existing jobs at Runcorn while creating new roles across additional shifts. The Rehau Group’s Window Solutions business operates three recycling sites across Europe, including facilities in Germany and Poland, processing 90,000 tonnes annually, and this expansion will see Runcorn’s shredding line become the largest in Europe.

“Rehau has always positioned itself as a premium supplier, and that means investing in the infrastructure behind our products, not just the products themselves,” said Russell Hand, executive vice president at Rehau UK. “What we are doing at Blaenau and Runcorn reflects a long-term view. We are building facilities that will serve our customers and the wider industry for decades to come.”

Both sites form part of Rehau UK’s ongoing commitment to strengthening its UK manufacturing operations, with further phases of development already planned through to 2028.