How a Composite Road Cone is made

Step One : Cone Base – This is made up of a number of raw materials including recycled cones – 15% of the base is recycled cone material. This mix is specific, ensuring that the end product is compliant with New Zealand requirements.

Step Two : Base material mix is loaded into a 365-tonne injection moulding machine and the base is manufactured. The base is then trimmed, and adhesive is applied around top edge. Quality checks are completed before the product moves to the next stage of production. Any rejected bases are cut up and put back through Step One of the process.

Step Three : The base is put into another 450-tonne injection moulding machine, to mould and attach the base to the cone upper. The upper is made from virgin PVC to ensure compliance with New Zealand requirements. Quality checks are completed before the product moves onto the next stage of production. Any rejected cones are cut up and put back through Step One of the process.

Step Four : Once the cone has finished moulding and quality checks have been completed, the reflective bands are attached.  The cone then moves to the next stage of production.

Step Five : The final step involves the painting and drying of the base. A water-based paint is applied to the base and the cone enters a drying line. Final quality checks are completed and the cones are then palletised, ready either for despatch or branding.  Any rejected cones are cut up and put back through Step One of the process.