Mass Production
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Nordell is well placed to service high volume production requirements on a global scale

Injection moulding is a fast, efficient and highly automated way to manufacture products. In mass production, in many cases, once the mould tool has been set in the press, the machine can be left to run on its own, allowing production to be completed quickly and without interruption.


Injection moulding is a highly cost-effective manufacturing process since it only uses the material required to make the part (additive) compared to other subtractive manufacturing processes that remove material, producing waste. The injection moulding process can be automated, reducing labour costs.


Injection moulding is a very flexible process that can easily be adapted to manufacture countless products using many different polymers, allowing the same part to be made with variable properties. Injection moulding is perfect for mass production since it’s fast and cost-effective.


Nordell is well known as a specialist technical injection moulder. However, we also balance our specialist injection moulding and manufacturing in conjunction with very high-volume mass production with annual parts volumes in the millions.

Cost-effective Mass Production

At Nordell, we will make sure that any mass-produced part is fully optimised to deliver a very cost-competitive part.


  • Our technical and tooling teams will review the tooling and, where possible, maximise the cavities to produce as many parts as possible on one injection cycle. There is a huge cost saving to be had by investing in multi-cavity tooling upfront rather than manufacturing parts over a longer production run. If you wish to review current tooling or discuss multi-cavity tool options, drop us a mail to
  • Mass production naturally lends itself to automation as the production runs are over a long period of time, and the ROI (Return on Investment) in automation is quick. Nordell can advise on automation options to reduce labour requirements and cost, whether this be a simple addition such as a conveyer to robotics to remove and pack parts.


Nordell has round-the-clock production across our core processes, including Injection Moulding, Finishing and Assembly, operating 24 hours Monday to Thursday and a Daytime shift on Fridays.


We plan and monitor all of our production using our fully integrated ERP system to ensure your orders are met on time and in full. Nordell will manufacture your goods ahead of demand, allowing for 5 weeks of demand deviation for customers who have regular, planned weekly orders.


Our highly effective planning teams work closely with our customers to agree forecasts. Using our rich ERP data source, we are able to track demand over a period of time, interrogating this data against previous demand patterns.


Nordell is well placed to service high volume and global requirements with DLF, Kanban and service to portal forecasts.


Our expanding global portfolio includes Europe, America, Canada, China & Korea.


Nordell has the scale to manufacture in batches of over a million parts, but if you only want a few hundred or less, don’t worry; we can do that too! Talk to us about your requirements, and we will be happy to offer you a cost-competitive solution, no matter how big your project.


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Our Robust Development Process:


Concept & Requirements

  • Discovery meeting or project/enquiry file review, for discussion to fully understand the product application and project performance, quality, timescale and budget requirements.
  • Provisional assessment of risk or variance to expectations, with brief to customer on initial observations and recommendations for approval prior to offer.

Design for Manufacture

Investigation and Development
  • Offer & Project Commercialisation.
  • Standardise materials, colours, number of parts, Inserts and build Operations.
  • Product and Design exploration with Sector cross pollination.
  • Initial FMEA & Control Plan.
  • Project Management.
  • Report & Proposals to Client.
  • Prototype and review.

Product Tooling Design & Manufacture

Tooling and Sampling
  • Design Freeze with 2D drawings & 3D files.
  • Tool Design GA customer approval.
  • Tool Manufacture.
  • Product & Tool identification standard for asset and labelling.
  • Product ERP structure, Centre selection, Bill of Materials and route standardisation.
  • Product materials procurement.
  • Production trials scheduling.

Product & Tooling Trials

  • Customer update.
  • Tooling and production trials.
  • T1 Sample submission.
  • Review, Tune & Development.
  • Tooling and Production Trials.
  • T2 Sample submission.
  • Sampling Review.

Product Part Approval

Verification and Validation
  • PPAP Product Part Approval Process.
  • First Article Inspection reports.
  • FMEA review.
  • Tooling Review.
  • Pilot production requirements.
  • Tooling Acceptance.

Product Approved

  • Transfer to commercial teams.
  • Product can be scheduled against production requirements.
  • Delivery terms reviewed (VMI, KANBAN).
  • Review.
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No matter what stage you are at in your thought process, make contact with our team today to discuss your project.
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