The Thermoplastics Group is mainly focused on the injection-moulding business. However, its portfolio is quite vast and mostly geared at international markets. With a number of facilities in Malta as well as in Tunisia, it comprises of various companies all steadily developing and looking out for the next innovative product.

Living by the maxim that strong enterprise never stops, Kenneth Caruana sets his standards high. Which comes as no surprise given his background as a private pilot and an aviation engineer. The Managing Director and CEO founded Thermoplastics in 1996 with a very modest set-up, largely based on his toolmaker experience. The Group currently employs around 365 persons, across a number of companies including Thermoplastics Ltd with manufacturing sites at the Marsa and Corradino Industrial Estates; Thermoplastics Tunisia SARL operating from Zaghouan, Tunisia; Aerotechnik; 2KR designs; Trovr Tech EU and Sandhill Ltd. Mr Caruana also headed Malta Wings and the Malta School of Flying.

With no qualms about having his sights on constant growth, Mr Caruana underlines that he considers business that does not seek to innovate as one in decline. And his ventures definitely do not fall under the latter category. Pointing out at recent projects, he provides a glimpse on some impressive initiatives that are in the pipeline.

Recalling 2KR Designs’ recent success story with the rapid manufacturing of visors for frontliners during the pandemic, Mr Caruana highlights how under the challenging circumstances of that period, the company delivered some seven million visors to the UK’s National Health Service, supplied Maltese authorities with around 100,000 visors and produced another 2 million that were provided to other countries. Mr Caruana notes that “During the Covid period, we manufactured in record time, face shields for many countries including Malta.” No mean feat, considering the logistical aspects such as those related to securing raw material and the manufacturing processes.

Mr Caruana also explains that discussions, now at an advanced stage, are being conducted by Thermoplastics with significant Chinese, German and American partners, with a view to establish ventures based in Malta. Eyeing the European plastic sector, and with Thermoplastics well acquainted with the market and equipped with decades of experience, the company presents an attractive proposition to partner with. Such a development is one to look out for, and may also be expected to reap further dividends across the board.

Thermoplastics runs the largest injection moulding operation in Malta, with some 200 such machines as Mr Caruana explains that these “vary from 5 ton up to 550 ton”. Mr Caruana acknowledges that Malta retains a competitive edge over manufacturing in Western Europe, and the Group ensures that this is well utilised. In recent years it acquired a competitor with all its operations in Corradino, including its personnel. Furthermore, the facilities in Tunisia gives its considerable edge “a boost”. Including a new factory with the latest technology, the complex measures some 5,000 sqm, allowing the Group to operate with ample capabilities in the European market. Mr Caruana also makes reference to a “new company to be set up in the coming months investing in additional eight big injection moulding machines, robots, automation and clean area.”

The company offers a complete service, with the ability to provide a finished product from the design stage on to its packaging. Mr Caruana lists various services effortlessly, noting that the company supports “pad printing, spray painting, blister packaging, thermoforming, plasma treatment, assembly and final packaging”. Furthermore, he notes that “the company is already producing products made out of bio plastics.”

The Managing Director also asserts that the Group was certified for environmental management systems such as the ISO 14001 standard on its own initiative and well before this became an obligation, being “among the first few manufacturing companies in Malta to be certified” to such a standard. He underlines that the company invests large sums to upgrade its machines, increasing efficiency while recycling all plastic byproducts at its own facilities, noting that “the company invested in plastic granulators to recycle byproduct in-house.”

Another notable element within the Group of companies headed by Mr Caruana is Aerotechnik. With a focus on carbon fibre, it offers a multitude of solutions from its separate facilities in Marsa, providing services in engineering capabilities with fibre, metals, polymers and the use of other chemicals. 

While many clients of the Thermoplastics Group tend to be large conglomerates and “established brands seeking high volume production,” Mr Caruana also makes it a point to note that the Group encourages partnerships with “innovators looking to commercialise their invention”. Mr Caruana reveals that his companies “also partner with universities”. These aspects mark the flexibility that the Thermoplastics Group employs as well as the strong drive on innovation, a characteristic that appears to permeate throughout Mr Caruana’s outlook and the Group’s multiple operations. He continues that “We are highly interested in helping develop new products from initial ideas to prototyping and production.”

Looking ahead, Mr Caruana sees the Thermoplastics Group as one that will face “big changes related to more sustainable investment, expansion of business, and new clients from Europe, Africa and Asia.” He also envisions that European customers will shift their preferences to EU based suppliers. And as Thermoplastics continues to develop, and never stop innovating including with the “development of our own innovative products,” one looks forward to hear more about this Group’s many success stories.

Main Image: Kenneth Caruana