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Chemicals Case Study: Getting a Critical Contract Back Under Control For Rutpen Ltd
When imported filling machines left Rutpen Ltd’s new client contract behind schedule, the Berkshire chemical manufacturer turned to UK manufacturer Cap Coder for a solution. We spoke with Managing Director Dave Roberts to find out how a re-engineered filling and capping machine, delivered in six weeks, restored reliability and strengthened the partnership, leading Dave to order a total of five Cap Coder machines.
About Rutpen
Rutpen has spent 50 years manufacturing chemicals, historically as a contract manufacturer for large multinationals in the industrial and institutional (I&I) cleaning sector. Much of that product leaves site in 5 litre and 20 litre containers, and high-volume chemistry remains the company’s core strength. When Dave Roberts became Managing Director 15 years ago, he moved the business towards specialist chemistry. Today, Rutpen combines specialist chemical manufacturing with a growing contract filling operation, serving customers across sectors including B2B, construction, cleaning and industrial applications.
The Chemical Packaging Challenge
A new, rapidly expanding client asked Rutpen to take on their product range. Speed to market was critical, so Dave reviewed three filling equipment suppliers, including Cap Coder. Rutpen chose a supplier offering imported equipment on a shorter lead time and bought two machines. Engineering and quality support never materialised, and the contract quickly fell behind.
“That was one of the only out-of-control contracts I’ve ever experienced in 35 years. As a business, we do what we say we’re going to do. If we say we’re going to deliver on Thursday, we will deliver on Thursday.”
Rutpen was open with its client throughout. Because the client valued Rutpen’s chemistry expertise and wider support, the relationship held while Dave looked for a fix.
The Solution: Chemical Filling and Capping Machine from Cap Coder
Dave went back to Cap Coder. This time, Cap Coder had capacity in its production schedule and a machine that had come back into the business. Cap Coder re-engineered it to Rutpen’s bespoke requirements in 6 weeks, a much shorter lead time than a new build.
Rutpen needed one machine to fill, cap and label, so Cap Coder brought in its labelling machine partner to deliver an integrated solution. With the first machine under way, Rutpen ordered a second, a Micro Mono rotary filling and capping machine. Three further machines are now on order, taking the total to five.
“One of the good things about Cap Coder is their reaction to put things right quickly.”
The Results: More Than Machines
The Cap Coder filling and capping machines now run all day, every day, on a single shift for the fast-growing client. Dave likes how compact and versatile the Cap Coder machines are: “The Micro, in particular, is so easy to use from an operator’s perspective, from an engineering perspective, and from a footprint perspective. They’re great.”
The support after the sale matters just as much. Every new container Rutpen takes on needs its own change parts, and Cap Coder turns these around quickly, so production never has to wait. Dave also values the people behind the machines. He finds the Cap Coder team really approachable and says communication is clear and friendly at every level of the business, whoever he happens to be speaking to.
Also, there’s the fact that Cap Coder builds its machines in the UK. Dave now buys directly from UK manufacturers rather than going through resellers or agents, and Dave is clear about why. “We will always buy UK for many reasons. None of them necessarily nationalistic. More about service, supply chain and speaking the same language.”
What’s next for Rutpen’s Contract Filling and Packaging Operation?
The success of the project has strengthened Rutpen’s commitment to expanding its contract filling and packing operation. Demand is growing from both existing and new contract manufacturing customers, so the business is investing in more liquid filling capacity and greater automation across its production lines.
The Cap Coder filling and capping machines handle a wide range of container sizes and product types. That flexibility makes it easier for Rutpen to onboard new contracts and respond quickly to changing customer requirements. As the filling operation continues to grow, Dave sees Cap Coder as an important long-term partner in its automation plans.
A Chemical Manufacturing Customer Experience
Dave Roberts, Managing Director, Rutpen Ltd
“We’ve built our reputation on delivering what we say we’re going to deliver. Having reliable, flexible filling equipment is a key part of that. As our filling operation continues to grow, we see Cap Coder as an important long-term partner.”
Supporting Chemical Packaging Now and in the Future
With several Cap Coder systems already installed and a proven performance record, Rutpen Ltd continues to rely on Cap Coder filling and capping technology as its chemical packaging operations grow. Industry events such as ChemUK Expo also help maintain the relationship. They give chemical manufacturers a chance to benchmark equipment, share insights with peers and explore new ways to handle a wider range of liquids, containers and closures.
We believe in meeting our customers face to face, showing our equipment working in person and talking directly with the people who run the machines. That openness and accessibility has always been one of our strengths.
More Than Machines: A Partnership Built on Trust
For chemical manufacturers, consistent capping integrity is essential to prevent leaks, protect operators and keep products compliant in transit. Achieving it while keeping production lines flexible and efficient is a complex challenge. Rutpen Ltd’s experience shows how a customer-led engineering approach, combined with robust and reliable filling and capping systems, can deliver long-term value well beyond installation.
By focusing on usability and close collaboration, Cap Coder continues to support chemical packaging teams with equipment they can trust and people they want to work with.
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