Manufacturing · Recycled plastics
A polymer recycling manufacturer's R&D claim
How a UK recycled plastics manufacturer turned regulatory and supply chain problems into a documented SME scheme R&D claim for the year to 31 March 2024.
The client
A UK producer of recycled PET sheeting for the food packaging industry, with around 25 staff and a turnover of almost £10 million. The company qualified as an SME for the period ended 31 March 2024, and was an established name in its field with a clear ambition to be the leading producer of its kind.
The challenge
- New food-contact regulations effective in July 2023 prohibited the standard layered structure the company used, so it needed a commercially viable new process and materials mix.
- Optical anomalies in its sheeting were causing market resistance, even though the material met hygiene standards, and the exact causes were unknown.
- An existing infrared dryer was designed only to dry flakes. Could it be repurposed to clean material well enough for anticipated tighter food-contact rules?
- Material shortages introduced new contaminants, such as PVC and rubber, that had to be removed without significant capital expenditure.
What we did
- Held detailed discussions with the company's competent professionals, challenging the level of detail until the narrative around each project would hold up to HMRC scrutiny.
- Applied the cost rules carefully. Staff time was assessed fairly and conservatively, only consumed materials, software and packaging were claimed, and utilities were apportioned in line with the staff costs claimed.
- Wrote a detailed technical report for each project, covering existing industry practice, the advance sought, the uncertainties and how they were resolved.
- Summarised the figures per project, showed the client the expected tax saving, and submitted the claim with the additional information form after management approved the report.
The outcome
- A claim of more than £600,000 of qualifying costs: around £175,000 of staff costs, around £400,000 of consumables and around £40,000 of utilities.
- Four well-evidenced projects, with a technical report approved by the company's management.
- A claim prepared under the SME scheme rules that applied to that period, with every cost backed by evidence.
What it shows
R&D is not limited to laboratories. Regulation and supply chain pressure can force a manufacturer to solve problems that nobody has solved before. What turns that work into a defensible claim is careful dialogue with the people who did it, conservative cost treatment and records that tie each cost to a project.
