Strong innovative culture and agile wheel and tyre production as well as in-house design and mould manufacturing. STARCO’s UK factory excels in injection moulded wheels, puncture-proof tyres and high performance tyres for industrial vehicles.

STARCO DML was established in 1997 with a focus on supplying automotive customers with for instance bushes, bearings and interior components. Later the factory found its niche and since 2005 where STARCO acquired the factory the focus gradually switched to wheels and tyres. Today, STARCO’s factory in the UK is one of Europe’s premier plastic wheel producers and the largest puncture-proof tyre manufacturer.

The factory excels in injection moulded wheels, puncture-proof tyres and high performance tyres for industrial vehicles. STARCO drives joint-development projects with major players in the industrial industry and supply world leading wheel barrow manufactures such as Altrad, Walsall Wheelbarrows and Hörby Bruk.

Despite a main focus on the wheel and tyre production accounting for more than 80 percent of the turnover, the team also use competences to serve other sectors, such as electronic, camping & leisure and the automotive industry. Previous customers have included Nissan, Bentley, Aston Martin, Volvo and Jaguar, where we supplied, tooling, injection mouldings and polyurethane foam components.

The polyurethane material used for our puncture-proof tyres is light-weight, hard-waring, has good shock absorption properties and demonstrates excellent resistance to most chemicals, ozone and UV attack. This ensures our products are first choice for many demanding applications.

The factory holds has an impressive safety record with regard to both absence and accidents. All products from this factory are fully REACH compliant meeting European standards and legislation – this helps to protect health and the environment by minimising and eliminating the use of potentially harmful chemicals.












By combining our manufacturing and design expertise with acute customer awareness, we are able to bring unique products to the market securing our future and providing our customers with significant market advantages.


We have a very close relationship with STARCOs steel wheel factory in Croatia, where we are able to generate component designs incorporating our tool making and polymer processing expertise with their steel wheel manufacturing capability. 

Currently, we are working on revolutionary wheel designs combining polymers and metals to provide extremely competitive products with outstanding performance.

STARCO has several patents in place for both polymer products and processes, which affords a major competitive advantage to us and our customers.


Read more about Research & Development in STARCO












The factory specialises in injection moulded wheels, polyurethane (PU) tyres and high performance tyres for industrial vehicles such as the puncture-proof STARCO flex-range and the innovative iCore puncture-proof tyre-range. The two main processes are: 

Injection moulding

This is the processing of thermoplastic granules that are melted and cooled in a mould. This is usually a very fast process, but relatively high investment is required for tooling. However, this process provides very cost-effective components. It is also highly accurate, repeatable and supports large volume requirements, with a significant level of automation. Components are produced from 0.5g to 2kg in a very wide range of engineering materials. Some of the more exotic polymers have a strength approaching that of aluminium.


Polyurethane reaction injection mouldings

This activity varies very much from the cooling /melting process of injection moulding. Two liquids are injected into a mould; and a reaction causes the material to expand and cure, at the same time filling the mould.

Not as fast generally as injection moulding, but simpler tooling with less investment required. Can still support high volume production, by increasing the numbers of moulds.

The Factory











The factory is located in Crewe, UK, has high automated standards and is working towards ISO 9001-2015.

Our factory is a well-equipped facility with:

  • 10 injection moulding machines ranging from 50 tonnes locking force to 500 tonnes,
  • 6 robots affording high levels of automation and efficiency,
  • 3 high pressure reaction injection moulding machines for polyurethane reaction injection moulding,
  • >1 low pressure machine for specialist polyurethane elastomers.


All products are REACH and PAH compliant. This means they: 

  • Contain none or limited restricted chemicals – complying to European standards
  • Protect health and environment by minimising and eliminating the use of potentially harmful chemicals
  • Do not contain polycyclic aromatic hydrocarbons

Read more about PAH and REACH at and STARCO’s CSR policy here.

In Brief

  • Located in Crewe, England
  • Established in 1997 and became a part of STARCO in 2005
  • Produces >500,000 wheels per year for the light transportation, agricultural implements and industrial segments
  • Capable of producing >6,000 tyres per day
  • Total factory scrap < 0.5%
  • REACH and PAH compliant products
  • Well-equipped tooling facility
  • Injection moulding wheel production (4" to 10")
  • Puncture-proof Polyurethane Tyre manufacturing (6" to 18")
  • In-house development team and great synergy with other fields of expertise in STARCO
  • 60% of the sales in 2015 included polyurethane (PU) tyres. In 2017 we expect it to be 80%



Unit 6 Marshfield Bank Emp. Park

Middlewich Road

GB-CW2 8UY Crewe - Cheshire


Phone: +44 127 025 3588

Fax: +44 127 025 3589


VAT: UK 833 6225 37

Driving instructions

Read more about clever wheel and tyre solutions for


Light Transportation   or   Industrial Vehicles   or  contact our sales team here