A family-owned business is taking on some of the world's biggest battery markets after transforming itself from a specialist distributor into an advanced manufacturer in just five years.
Avocet Materials Group has built a 29-strong manufacturing and R&D operation in Holmes Chapel, Cheshire, developing specialist components for lithium-ion batteries which it says had previously only been manufactured in Asia.
Its products are used within Formula One (F1) battery applications, as well as aerospace, defence, electric vehicles and energy storage applications. The business exports 99% of its battery products to markets including China, Japan and the US.
Now, having grown turnover from £1.5m to £3.5m, including around 25% sales growth this year, the speed and scale of Avocet's transformation has prompted the company to take stock of the systems, technology and leadership needed for its next phase.
It is working with Made Smarter North West, the government-backed programme helping SME manufacturers grow and innovate through digital technology and skills, to improve productivity, increase capacity and build the foundations for further expansion.
Kieren Hall, CEO, said:
“When you think that five years ago we didn't manufacture anything, what we've achieved is pretty remarkable. We've built a manufacturing operation from scratch, developed our own technology and we're now making specialist components for lithium-ion batteries in Cheshire for some of the most demanding applications in the world."
“We're exporting 99% of our battery products and selling into countries with some of the biggest battery industries in the world, including China and Japan. For a business of our size to be competing internationally at that level is something we're incredibly proud of.”
Founded in 1996 by Kieren's father, Graham, Avocet began life as a specialist metals distributor before moving into manufacturing during the Covid-19 pandemic.
Backed by a £1.4m Innovate UK grant through the Advanced Propulsion Centre and further investment, it has since developed into a group spanning Avocet Precision Metals, its specialist metals distribution business; Avocet Battery Materials, its manufacturing arm; and Avocet Research Centre, its R&D operation.
At the heart of the business are lead tabs, small but critical metal components which connect a lithium-ion battery cell to the outside circuit. They can influence weight, conductivity and reliability and must be manufactured to exacting standards for high-performance applications.
Avocet's innovations include Flyweight, its bimetallic lead tab for pouch cells which is used within F1 battery applications to reduce the weight of the battery system.
It is also developing DryTab, a next-generation surface technology which recently secured government backing through the DRIVE35 programme.
But the pace and ambition of Avocet's expansion has created a new challenge, with its systems and processes struggling to keep up with its rapidly evolving manufacturing operation.
Avocet turned to Made Smarter for support, securing a £13,000 grant towards a £75,000 ERP system. Going live in January 2027, the technology will integrate operations across the business, improve productivity and give Avocet the digital infrastructure it needs to scale.
Made Smarter has also supported Kieren through its Leading Digital Transformation programme, helping him develop the strategy and leadership capability needed to drive the business forward.
Kieren said:
“We've grown incredibly quickly and there comes a point where you realise the systems and processes that got you this far aren't necessarily the ones that will take you to the next stage."
“Working with Made Smarter has given us the opportunity to take stock and look at the business differently. We're putting the right digital infrastructure in place, but it's also helped me think much more strategically about how we lead the business, where we're going next and what we need to get there.”
Avocet is already looking to its next manufacturing challenge, exploring automated inspection technology to increase production capacity, alongside opportunities to use AI to improve efficiency and decision-making across the business.
Donna Edwards, Director of Made Smarter North West, said:
“Avocet is a fantastic example of the ambition and innovation within UK manufacturing. In just five years it has built advanced manufacturing capability here in Cheshire, developed its own technology and is now competing successfully in global battery markets."
“Rapid expansion on that scale brings challenges as well as opportunities. Made Smarter is there to give ambitious SME manufacturers access to the right technology, skills and leadership support at the right time, helping them turn that potential into sustainable growth. It is incredibly exciting to see what Kieren and the team have achieved and to support them as they prepare for what comes next.”
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