At Walker Rubber, we pride ourselves on making rubber supply simple. We thrive turning complex challenges into dependable solutions. Whether that’s sealing a hatch, protecting a slipway, or in this case, protecting aircraft on the ground. We’re known for manufacturing quality rubber products that perform in real-world situations, no matter the industry.
This time, we were approached by a long-standing customer in the civil engineering space with strong ties to the aerospace and aviation sectors. They had an urgent need for a robust rubber fendering system for their growing fleet of aircraft ground support equipment vehicles.
With demand for their equipment steadily increasing, they needed a rubber manufacturer and supplier who could keep pace and meet their requirements.
Who is the customer and what did they require?
Our customer is a UK-based civil engineering company that manufactures specialist ground support equipment. They make everything from de-icers, to hi-lifts, stair lifts and more, which are used to prepare aircraft for take-off, help passengers embark, and carry out critical maintenance in between flights.
Their vehicles have to operate quickly and efficiently to meet the exacting timeframes demanded on the tarmac - so damage protection is vital to protect aircraft, equipment and ensure airport operations go as planned. This is where our rubber fenders come in.
After a previous supplier struggled to meet their demand, our customer returned to Walker Rubber; an old partner they knew they could trust for their requirement:
- 500 customer D-profile rubber fenders
- Deliveries made in monthly batches of 50 over an 11-month schedule
- Durable enough to protect both vehicles and aircraft in everyday use
- Precisely cut and drilled for easy installation
It was a considerable step-up from the 80100 parts we used to supply to this customer each year, but we were ready for the challenge!
What solution did Walker Rubber provide?
After receiving the enquiry, our first step was to review the design and technical requirements of the rubber fenders. They needed to be large, heavy-duty D-profile (108x92mm), cut into 450mm lengths and drilled to ensure they could be mounted securely.
Thanks to our in-house tooling capabilities, we were able to get started straightaway.
Process
Custom tooling: Due to the fendering's size, we used specialised machine tooling to achieve the dimensions needed.
Extrusion: We extruded the fenders in-house at our manufacturing facility in Norwich.
Precision drilling: we drilled mounting holes with great precision as they needed to be clean and consistent, so the fenders could be mounted easily to the front and back of the vehicles.
Fast turnaround: With the new drill bit and process in place, we completed the first batch of 50 fenders in less than a day.
Were there any challenges?
As we started producing batches of the fenders, we noticed that our standard drilling process was sling us down. Switching drill bits mid-run was adding significantly to our production time, and with a tight monthly delivery schedule, wasn’t sustainable.
To increase our efficiency, we invested in a custom drill but that allowed us to drill the mounting holes in one seamless operation. This small but crucial change kept us on schedule and improved the consistency of the finished product.
What was the result?
The result was a high-volume, high-quality supply of fenders that met our customer’s specifications and was delivered every month on time.
The custom rubber fenders now provide essential protection for our customer’s ground support equipment across their global fleet; helping prevent costly damage and extending the service life of the equipment.
More than that, this project cemented and reinvigorated a valuable partnership with a long-standing customer.
Looking for a reliable supply of rubber fenders?
From heavy-duty fendering to precision extrusions, Walker Rubber has the expertise and manufacturing capabilities to deliver exactly what you need: on time, at scale, and of quality you can rely on.
Fill out our contact form today to get started!