Hurst Green Plastics Co-Founder Sadly Passes Away

Helen Clarke, who was the joint founder of Hurst Green Plastics, sadly passed away this week after a short illness – she was 96.

She lived to see the Company she founded reach 40 years of trading this August.

Helen worked as Financial Controller and was still working in the office two mornings a week, up until she was 92.

She will be greatly missed by us all.

TwinBin Live! The latest advancement in inventory management and cost control

The latest, most technologically advanced addition to the TwinBin range is now here – TwinBin Live.

TwinBin Live further develops the TwinBin range by adding cloud-based functionality, coupled with instantaneous stock control.

The TwinBin range has been developed using KanBan methodology.  It is a system that works by storing reserve stock above active stock. Once the active stock has been depleted you simply pull the slider to release the reserve batch leaving the upper chamber ready for new stock.

TwinBin Live updates in real time, anywhere.

This means full control at all times, bringing cost savings, as inefficient stock control can cost significantly in terms of both time and money.

What are the benefits of TwinBin Live?

  • Cost control and savings
  • Full parts traceability
  • Reduces stock held
  • No missed scans
  • Provides a fully secure communications network
  • JIT (Just In Time) delivery
  • First In First Out (FIFO) stock rotation
  • Fully modular – Easy to change and adapt to changes in workflow.
  • Quick and easy to install
  • Fits seamlessly with existing TwinBin systems

TwinBin Live incorporates a full cloud-based data feature set, with an Android-based app for simple access and full management reporting.

The TwinBin Live components themselves incorporate a battery-based power source, with a 7+year life, meaning no power supply required to the racking.

The TwinBin Live bins also carry “intelligent” functionality, meaning they can prevent sabotage from staff and also monitor their own battery life.


Inventory control and inventory tracking can bring significant cost savings in the long run.

Proper inventory management means less stock lost, less time invested and more efficient processes.  TwinBin Live can make this process as straight forward as possible, with full control at your fingertips, anywhere and anytime.

Adhering to Kanban principles, TwinBin Live adds Bluetooth and cloud-based functionality to an already proven stock management system, TwinBin.

The most basic and simple implementation of a Kanban system can be done through a two-bin system.

There needs to be a trigger in the Kanban system to display a visual signal once the replenishment request has been activated. This can be a simple signal such as a Kanban card or something complex as an RFID Alert, or in the case of TwinBin Live, fully automated bin scanning.

Imagine the convenience of automatic stock reordering – simple, effective and minimal management time.


At its simplest level, TwinBin Live facilitates Kanban methodology in any production or process environment incorporating the system.

Kanban is a methodology in lean manufacturing which manages and improves workload within production.

From Japanese roots in automotive manufacturing environments, the word ‘Kanban’ can be roughly translated to mean ‘Visual Signal’ and is used as a Just-In-Time (JIT) method of inventory control.

The aim of a Kanban System is to eliminate excess inventory throughout the production cycle and align inventory levels with actual consumption, whilst highlighting any inefficiencies within the supply chain.


The most basic and simple implementation of a Kanban system can be done through a two-bin system.

Please see below our guide to implementing a simple two-bin system:

  1. Firstly, gathering information and planning is crucial for all items wishing to be stored in a Kanban system. Important information such as quantities used, the lead time and product MOQs need to be understood and analysed for the two-bin system to work. If this is not completed correctly then there may be too much, or too little stock available and the system will fail.
  2. Once enough data has been gathered and researched, it is time to implement the two-bin system. The stock needs to be placed in the two-bin system, ensuring the second bin contains enough stock for production to continue once the stock replenishment trigger has been activated – this information should be available from all the data gathered during the planning stage.
  3. There needs to be a trigger in the Kanban system to display a visual signal once the replenishment request has been activated. This can be a simple signal such as a Kanban card or something complex as an RFID Alert (or by using our TwinBin System which does this for you!).
  4. Ensure that production begins with the first bin, which we call the ‘Active Bin’. Once the stock is exhausted, production moves on to the second bin, which we call the ‘Reserve Bin’. Once the reserve bin comes into play, it then changes to become the active bin. A visual signal then needs to be triggered in order for stock movement requirement to be activated.
  5. Once more stock has become available, this needs to be placed into the (now empty) reserve bin and placed back into production to be utilised once the active bin is exhausted.
  6. Once the reserve bin has been replenished, this then resets the cycle whilst production continues.
  7. It is important to note that regularly returning to the planning stage is crucial to ensure to the efficient running of the Kanban system, regularly checking for changes in lead times, MOQs and changes in production that can influence the Kanban system.

There’s a birthday about… Hurst Green Plastics Ltd celebrates 40 years

40 years of innovation

From humble beginnings in a little village in the Ribble Valley, Hurst Green Plastics Limited proudly turns 40 this year and is celebrating by launching a brand-new product.  Hurst Green Plastics Ltd began in 1979, when Chairman Stephen Clarke bought the company, in the little village of Hurst Green, Lancashire. The factory had originally been opened in 1860 to make wooden bobbins for local cotton mills but had switched to injection-moulded plastic in 1955.

Stephen developed the company and developed a variety of innovations which determined the path the company was going to take.   One of the fateful innovations was a hands-free dispenser for nuts, which was seen by an Airbus Executive in his local supermarket, which created the idea of the same system, but for rivets within their facility – creating the Rivet Dispenser and the first step into Inventory Management within the Aerospace Industry. Working with the Aerospace Industry lead to further developments for inventory management and the introduction of new products such as the multi-award-winning TwinBin System.   Hurst Green Plastics Limited moved its headquarters to Whalley and the innovations continued with the release of the patented BinFlag, SpinFlag, Kitting and TripFlag Solutions.

Hurst Green Plastics Limited now export their product range globally to some of the largest Aerospace Manufacturers in the world and have branched out to new industries including Rail and Hospitals. They are currently working on the launch of a brand new system, TwinBin Live, which takes all the benefits of the TwinBin System and incorporates it with Bluetooth, NFC and cloud based software to create a real-time, 24/7 inventory management solution which will revolutionise stock management.  For more information on TwinBin Live, and to claim your free TwinBin Live brochure, sign up to our newsletter here.

We look forward to another 40 years!

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Hurst Green Plastics Ltd will be attending the 53rd Paris Airshow 2019

Hurst Green Plastics Ltd will be attending the 53rd Paris Airshow 2019, which runs from 17th to 23rd June 2019. The Airshow takes place at Le Bourget Parc des Expositions in Paris and will bring together Companies and visitors from around the world. The previous show, in 2017, received over 322,000 visitors across the 7 days visiting 2,381 exhibitors and 140 aircrafts

Managing Director, Tommy Sharples and Accounts Director, Julie Monaco will be attending the show complete with all our latest products, available for demonstration.


Managing Director Tommy who has attended the show for the last 10 years, had this to say :

‘Le Bourget is a fantastic opportunity for us to meet with new and existing customers. We are thrilled to be able to demonstrate our brand-new products at the Paris Airshow for the first time”

Following the success at Farnborough Airshow, the team will be demonstrating our new solution TwinBin Live.  TwinBin Live offers 24/7, real-time stock updates, which can be seen anywhere worldwide.  You can find out more about TwinBin Live here and sign up to our newsletter to be the first to know when the new product launches.

If you would like to arrange a meeting with a member of the team then please visit here

If you can’t make the Paris Airshow 2019 but still wish to receive a demonstration of our new solution, TwinBin Live, why not contact the office to arrange a meeting with the team:

T:  +44(0)1254 825 588


Please check out our social media to stay up to date with our new product launches:


BAE Systems wins award utilising the TwinBin RFID System and SMT Reel Indicators to Boost Productivity

Smart Factories are now becoming a priority as manufacturers begin to utilise the Internet of Things (IoT) Technology within their facilities in order to connect people and machinery which has the possibility to generate endless amounts of data throughout their supply chain boosting productivity and visibility.

One of the companies prioritising the Smart Factory is BAE Systems and this article focuses on how they significantly boosted their productivity using Radio Frequency Identification (RFID) incorporated with the TwinBin System and SMT Reel Indicators winning them the award of Best Manufacturing RFID Implementation at the 17th annual RFID Journal Live Conference after demonstrating significant savings using the technology

The Story

BAE Systems, a global defence, aerospace and security company had a requirement to find and implement new technologies and new techniques in order to accelerate manufacturing processes to meet ever-growing customer demands.  In order to achieve lean manufacturing goals to increase manufacturing output, BAE Systems sought a solution in which materials could be replenished using a ‘pull’ methodology, based on just in time (JIT) demand, rather than the ‘push’ system in which materials are stocked based on forecasted demand, which was currently in place.

The company had a manual process for managing inventory in place, this process included manual barcode scanning in order to track and replenish inventory across a variety of sites and feeding this information to Procurement, who manually placed orders with relevant suppliers, leading to longer lead times and errors within ordering.

TwinBin RFID with RFID Tag

BAE Systems’ Electronic Warfare Integrated Manufacturing Center in Nashua, New Hampshire contacted Hurst Green Plastics Ltd in order to implement the TwinBin RFID System into their facilities in order to manage materials which are on site.  The TwinBin RFID System needed to be integrated into the Company’s Enterprise Resource Planning (ERP) systems providing an automated, real-time visibility solution, enhancing factory tracking and awareness capabilities within their ramped-up production efforts.

The TwinBin System was installed within the facility alongside RFID Technology providing BAE Systems with the information they required.  The TwinBin System, a two-bin system which contains stock within two chambers (an in-use stock chamber and a reserve stock chamber), can be RFID Compatible, which means once the slider is pulled to access the reserve chamber, the flag pops up, exposing a passive RFID Tag which is then readable by RFID Readers.  The RFID Readers scan the bins once each day to obtain data from any exposed tags to determine which parts require replenishment, orders are then automatically generated every night, and parts arrive at a pre-determined time within the Material Center providing a completely automated process.

Following the successful implementation of the TwinBin System, BAE Systems contacted Hurst Green Plastics Ltd once again with a requirement for inventory control of their SMT Reels. Working with the team at BAE Systems, Managing Director Tommy Sharples and Product Design Engineer Specialist John Whipp worked meticulously to design, create and test the SMT RFID Reel Indicator.  The SMT RFID Reel Indicator works by shielding the passive RFID Tag when the product is full. Once the product is removed, the flag pops up and exposes an RFID Tag which can then be read by RFID Readers, automatically generating orders each night.  The team at BAE Systems successfully trailed the SMT Reel Indicator over a number of months, leading to their first order of 8000 units for the facility in Nashua.

SMT Reel Indicator

The Success

Today, BAE Systems has more than 9,000 individual part numbers that are actively available for automatic replenishment saving approximately 2,400 hours each year which drove them to victory at the 17th annual RFID Journal Live Conference in the category of best RFID Manufacturing Implementation.

 “The BAE Systems’ program was an excellent example of how RFID and the right software can drive real value for companies. It was truly an award-winning project that demonstrated how RFID can translate into quantifiable results for a major enterprise,” said Mark Roberti, founder and editor of RFID Journal.

The conference is the worlds largest RFID Venue with several other international companies vying for the award. A highlight of the conference was the keynote address provided by Diedre (Dee) Schmidt, BAE Systems Operational Excellence Leader who championed the RFID initiative at the facility in Nashua. She discussed the program’s journey in automating the inventory replenishment process – you can see this here.

For more information on The SMT RFID Reel Indicators, click here

For more information on The TwinBin System, click here

For more information on our RFID Solutions, click here

Did you know we are launching TwinBin Live? Incorporating Bluetooth and NFC to create a completely automated real-time 24/7 solution.  To find out more click here


The TwinBin Shop is now live!

The TwinBin Shop has now launched!

We are delighted to confirm that The TwinBin Shop has now launched.

You can now order products such as:

  • BinFlag Stock Indicator
  • SpinFlag Stock Indicator
  • Open Tote Bins
  • Clearbox Storage Dispensers

The shop can be found at

We are adding new products each week, so keep an eye out!

Open Bin with BinFlag

You can order the goods, add them to your cart and pay there and then.  We are making order storage handling equipment easy with TwinBin Shop.  We accept all the major credit cards.  Want a large quantity?  Then just email us on:

TwinBin Shop: Products Available

These are just a few of the products that are currently available!

SpinFlag Stock Indicator

The SpinFlag Stock Indicator is a small round kanban stock level indicator which can be placed at the front of open tote bins and shelves to display stock level status.    Simply change the colour to display the stock level status:

Green = Stock levels good

Red = Replenishment Required

Yellow = More stock on order/Item scanned

The SpinFlag is 36 x 36 x 17mm, which is probably small enough to place anywhere you need to track stock levels

Find out more about the SpinFlag here

SpinFlag Stock Indicator

BinFlag Stock Indicator

The BinFlag Stock Indicator is a rectangular kanban stock level indicator which can be placed at the front of open tote bins and shelves to display stock level status.  Simply change the colour to display the stock level status:

Green = Stock levels good

Red = Replenishment Required

Yellow = More stock on order/Item scanned

They are available in two sizes:

  • Small   80 x 45mm
  • Large  112 x 50mm

Our BinFlags are RFID Compatible so you can be future ready!

Find out more about the BinFlag here

Stock Indicators

Other Products

We will also be offering Open Tote Bins, ClearBox Storage Dispensers and a variety of other storage and handling solutions. Why not head over to the shop to see what available?  Visit the shop here

We are also posting deals on our Social Media Accounts.  Why not head on over and give us a follow/like and get the best deal.


3 products that implement kanban inventory management effortlessly

The main purpose of implementing a kanban inventory management system is to maximise output by reducing waste.  You can read about what Kanban is here.  By reducing waste, it means that everything passing through the kanban inventory system is adding value to production and anything not adding value is a waste.  This concept is also known as Lean Manufacturing.

As inventory management is becoming ever more important in order for production to flow as effortlessly as possible, yet not wanting to have finances tied up in stock that won’t be used for months, there are now products readily available on the market that can help you easily implement the principles of kanban inventory management and lean manufacturing into your workspace without having to make major changes to the way you operate

Kanban Inventory Management by Two-Bin System

The Two-Bin System works on the concept that there are two bins per product line.  This is often utilised with plastic open bins.  There are different ways to incorporate the Two Bin Systems, such as using different coloured bins to represent different stages in the inventory cycle or using different coloured barcodes at the front of the bins.  The bins are often housed in a form of racking and work on a front to back system, with the reserve stock being placed at the back.

Once the front bin has been exhausted, the operator simply starts working from the back bin and can place the empty front bin in a location to signal the re-ordering process.

Once the next batch comes along they just place this behind the bin that is in use and then the cycle can continue.

This option is an easy way to implement your kanban system and works well with both large and small components.

Two Bin System
Two Bin System
Stock Indicators
Stock Indicators

Kanban Inventory management by Visual Stock Level Indicators

Stock Level Indicators by are a quick way to display stock level status without having to change anything! They simply attach to the front of shelves/cabinets/bins and display the stock level status:

  • Green  Product is in stock
  • Red   Product needs re-ordering
  • Yellow  More product is on the way

If you are unable to change the layout of your storage areas but want to implement kanban, this is a great place to start.  Stock Indicators are conscious of space requirements and are available in 3 different sizes meaning you can attach them almost anywhere to start your kanban journey.

Find out more about Stock Indicators by here

Kanban inventory management with The TwinBin System

The TwinBin System by is an innovative kanban system based around the concept of the Two Bin System discussed earlier and here.   Instead of having two-bins operating on a front to back system, the TwinBin System works with a top and bottom chamber.  Once the stock is removed from the bottom ‘in use’ chamber, the operator simply pulls the slider in the middle to access the reserve stock.  Once the slider is pulled, the innovative Flag pops up to display a red signal meaning that more stock needs to be ordered, whilst providing enough product for the operator to continue working. Once more stock in on the way the flag can be set to yellow displaying this status.  Once more inventory is available, this is placed into the top chamber and the flag is set back to green, ready for the cycle to continue.

You can find out more about the TwinBin System here

TwinBins being used in Mexico

If you want any further information about the products listed above, then contact us as follows:


Telephone:  +44(0)1254 82 55 88

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Come and see TwinBin at the Avalon Airshow!

What is the Avalon Airshow?

Avalon Airshow 2019 24th February to 3rd March 2019

Hurst Green Plastics Ltd are taking the TwinBin System across the globe to the Avalon Airshow in Australia later this month.  The Avalon Airshow, which takes place at the Avalon Airport in Geelong, Victoria will run from 26th February to 3rd March 2019.  The previous show in 2017, saw 664 companies from 25 countries showcasing their products and services to over 33,000 trade visitors. This is the third time in 6 years that Hurst Green Plastics will be at the event showcasing our product range, and we are excited to show the Australian market all the new products and solutions that we have been working on.

What are we showcasing at Avalon Airshow?

The team will be taking a variety of products for demonstration such as:

We are also going to be bringing two brand new solutions to the show:

Kitting Solutions, BinFlag Stock Indicator and The TwinBin System
Ravn Aircraft and the TwinBin system

Accounts Director, Julie Monaco will be heading across the globe to the event and had this to say:

“It will be the third time that Hurst Green Plastics Ltd have taken the solutions to the Avalon Airshow and I am very excited to be joining Chairman Stephen and HR Director Martine at the event.  The show is a great opportunity to show the Australian Market what we have been working on and we are thrilled to show our newest solution TwinBinLive, which will change the way people control their inventory.”

If you would like to arrange a meeting with a member of the team then please contact us as follows:

Want to keep up to date with all our events and new product launches?  Then follow us on social media:


What is Kitting and why should you try it?

Kitting:  What is it?  Why should you try it?

Inventory kitting is the process of grouping and packaging separate items together into one-part number based on the requirement within the process. Kitting can save time and money by reducing unnecessary inventory and only using what you need, exactly when you need it.  Kitting can have the following benefits:

  • More Space Available: By reducing inventory you can reduce unwanted stock and free up space within your facility.
  • More Time Available: By having what you need as you need it, the process takes less time meaning you can get more done!
  • More Cash Available: By not having your money tied up in inventory, you can have better batch control and more cash available to spend on things that you really need.
Nuts and Bolts

Kitting can be as simple as putting the parts you need into a cardboard box and storing them together until they are needed but it can be also as complex as 20+ different part numbers being packed together in complex storage conditions.

With constant pressures on turn around time of products, kitting can be a great way to reduce lead times by having parts ready in a ‘grab and go’ system created through kitting and sub-assembly.

What kitting solutions are available?

Kitting Solutions by are a cost-effective solution as they are re-usable, re-sealable and durable.  Having a kitting container that you can use and re-use is a great way of storing and transporting goods around site. We have a variety of different solutions that can be utilised including:

Kitbox System:  Small boxes (kitboxes) placed inside a larger carry case.  Available in a variety of kitbox and carry case sizes, The Kitbox System is a flexible solution to storing your kitting components.  Tamper-proof mechanisms are available for the kitboxes so you know if the contents have been compromised before accessing them. The modular integrated lego peg base on the carry cases means that the kitboxes do not move around the carry case when in transit and sit flush next to one another, once in the case. The ticket holder on the top of the kitboxes can store your barcodes reflecting the contents of the kitboxes whilst keeping them clean from dirt or debris that may be seen in the production work space.  If you would like more information, or if you require a quotation then click here.

Kitting Kitbox Case by
Partition Kitting Case by

Partition Kitting Solution:  The partition kitting system is our solution if you need flexibility when it comes to kitting.  The Partition Kitting Case can be made into almost any configuration utilising the different partitions to suit the size of components or parts that need storing.  The durable, stackable carry case means that you can transport your contents around site whilst keeping them safe from damage.  All our kitting solutions are available with a glass-clear lid meaning that you can see what is inside without opening.  Want to learn more? Visit our Partition Kitting page here

If our solutions are of interest, then why not request a sample here and try the product before you buy?


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Two-bin system: How they work and why you should chose them

What is a two-bin system and how does it work?

A two-bin system is the easiest way to implement a kanban system into a manufacturing or production facility. Kanban is a methodology in lean manufacturing which manages and improves workload within production.  Originally developed in Japanese automotive factories, the word ‘Kanban’ can be roughly translated to mean ‘Visual Signal’ and is used as a Just-In-Time (JIT) method of inventory control.

The aim of a Kanban System is to eliminate excess inventory throughout the production cycle and align inventory levels with actual consumption, whilst highlighting any inefficiencies within the supply chain.

A two-bin system is actually exactly what it claims to be – managing inventory through the use of two-bins. The concept of a two-bin system is that operators will feed from one bin whilst using the second bin for reserve stock.  Once the first bin has been exhausted of contents the operator will start feeding from the reserve stock whilst triggering a signal that more stock is required.  The signal can be as simple as the colour of the bin or as complicated as RFID signals being sent to receivers and automatically placing an order with suppliers. Once the next batch of stock is available, it is simply placed back into stock for the operator to work from once the current batch is exhausted. The two-bin system creates a cycle, replenishing when required whilst creating a demand for the next batch – if implemented correctly, it should mean you are one step ahead of your requirements.

TwinBin: a two-bin system

Benefits of a two-bin system

Two Bin System and Aeroplane

There are many benefits that can be seen when utilising a two-bin system, which can include:

  • Reducing inventory held and therefore the associated costs
  • Traceability of stock
  • Easy to maintain once installed if appropriate planning is maintained

A reduction of inventory held is a positive byproduct that can be seen when implementing a two-bin system, because only holding the stock you need means that you haven’t got finances tied up in stock that isn’t being utilised for weeks or maybe months, whilst also promoting traceability of parts through batch control which is stored in each bin.  Once all the planning is complete, it is important to monitor aspects that may affect the two-bin system, such as spikes in manufacturing which may lead to a higher demand for stock. A two-bin system can fail if insufficient planning has taken place.  It is often advised to understand the demand for the product and ensure that all reserve batches contain enough product, whilst taking into consideration the lead-time of the next batch.

If you want to learn more about what Kanban is and how to implement your own two-bin system, then check out our blog here.

We have made kanban simple with our unique TwinBin System check it out here

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