Dorset-based manufacturer William Hughes is celebrating the 20th anniversary of its advanced fabrication facility in Plovdiv, Bulgaria, which has grown significantly since its establishment in 2004.
The factory, which originally spanned just 1,000 square meters and employed 13 staff, now covers 7,500 square meters and boasts five machining bays, a modern office suite, and a workforce of 175. This expansion represents a nearly seven-fold increase in operational capacity over two decades.
The Bulgarian operation has played a key role in meeting the growing demand for springs, wire forms, and wire assemblies, particularly within the automotive sector. Its strategic location has enabled William Hughes to serve both emerging markets in Romania, Serbia, and Turkey, as well as established markets across the UK, France, Germany, and Poland.
In addition to fulfilling orders for European customers, the Plovdiv facility also supplies parts to the company’s Dorset headquarters, where they are stored and distributed to UK clients. This setup allows William Hughes to offer competitive pricing by leveraging the cost advantages of Bulgarian manufacturing without the logistical challenges often associated with sourcing from lower-cost regions.
Emma Burgon, engineering director at William Hughes, attributes the success of the Bulgarian site to the company’s proactive approach to shifting industry trends. “We recognized where the market was headed two decades ago and made the bold decision to establish a local presence. This foresight has paid off tremendously,” she said.
To meet rising demand, the Bulgarian facility has expanded its technological capabilities. It now operates 35 CNC wire-bending machines, seven vertical and two horizontal injection-moulding machines, and two nylon plastic-coating lines. The facility also features advanced welding capabilities, including MAG, MIG, and spot welding, along with seven robotic welding cells. Additional enhancements include an Electrophoretic black paint line and Deltatone Finishing.
As the automotive industry continues to evolve, William Hughes remains committed to strengthening its position as a versatile supplier to multiple sectors. The company aims to maintain its reputation for high-quality design, engineering, and manufacturing, while offering competitive pricing and ensuring timely deliveries.