Pro Alloy Group are one of the world’s leading designers and manufacturers of specialist alloy components. For over two decades the Pro Alloy team have been specialising in the design, development & production of cooling and fuel system components for broad and diverse customer base, into a multitude of different industries.
As well as serving the Motorsport and Automotive industries, Pro Alloy provide products and services to a broad spectrum of non-automotive clients - Aerospace, Military, Defence, Marine and commercial vehicle applications.
Pro Alloy’s ‘Performance Driven’ approach to every aspect of the business has generated a reputation as one of the most respected and innovative manufacturers of Radiators, Intercoolers, Oil Coolers, Charge Cooler Systems, Fabricated Alloy Pipe work, Water Header tanks, Oil Breather Systems, Fuel Tanks and associated fuel system components.
Over the past two decades Pro Alloy have designed, developed, tested and now carry in stock an extensive range of ‘Off-the-shelf’ aftermarket performance products which are sold via the company’s worldwide dealer network, and directly to retail clients via the webshop www.proalloy.co.uk
In addition to this, Pro Alloy are also the desired choice by many Manufacturers, Race Teams, Automotive Specialists, Tuning Companies and OEM’s, to design and produce bespoke parts, building either individual custom one-off parts, or batch production parts to each client’s specific requirements.
With a passion to provide the best possible service and solutions to our customers, Pro Alloy strive to continually evolve, develop and improve every facet of the business, bringing many elements of the complex manufacturing processes in-house at our UK manufacturing facility in Haverhill, Suffolk.
With our in-house www.procores.co.uk heat exchanger production facility and our exceptional team of skilled engineers and fabricators, Pro Alloy are able to provide our customers with optimum design flexibility, manufacturing control, efficient production times and a ‘one-stop-shop’ for a broad range of associated products and services. This combined with our highly knowledgeable technical team, provides our customers with an exceptional and un-rivalled service.
LIFE BEFORE PRO ALLOY
COMPANY OVERVIEW
Pro Alloy Motorsport was originally formed by Alex Osborn and Wayne Clayden in January 2004, however, the origins of the company and its background in Motorsport Engineering extend back much further.
Alex comes from an extensive engineering background working for a number of years as a Senior Technician, Workshop Supervisor and Project Leader at TWI (The Welding Institute). TWI was, and still remains a global leader in technology engineering providing research, consultancy, and training in welding and joining technologies. During his years at TWI, Alex benefited from the opportunities to gain extensive knowledge, training and experience within the many specialist areas and departments of TWI. Predominately based in the company’s Power Beam Group, Alex became responsible for the development and operation of the company’s pioneering 100kW, 150m3 high vacuum Electron Beam welding facility, which at this time was the largest and most power machine of its type in the world.
From an early age Alex had a strong interest in Motorsport, spending many weekends as a child at the numerous hillclimb and sprint events around the UK. Whilst working at TWI in the early 90’s, the opportunity arose to work with a number of UK Motorsport engineering organisations. This opportunity ignited Alex’s passion for both Engineering and Motorsport. Throughout the 90’s Alex continued to work very closely with some of these organisations, and in particular working on FIA approved fuel systems for one organisation and Heat Exchanger manufacture for an another – Pace Products. With the demand for Alex’s input and services in these areas growing, in 1999 Alex left TWI and started ARO Motorsport Engineering, a specialist engineering company focusing on designing and manufacture of high spec, one-off motorsport parts, primarily focused on Fuel System components, Dry Sump Systems and Automotive & Motorsport radiators, Intercooler and Oil Coolers.
During the 90’s Alex had formed a close working relationship with Pace Products and its owner David Lazenby and heat exchanger department manager Wayne Clayden. David’s illustrious career in Motorsport was most notably his years as chief mechanic at Team Lotus F1 during the Jim Clark era which, in 1965, took David to the Indianapolis 500 where Clark won the world championship. David went on to create Hawke Racing cars and then in the 80’s started Pace Products, specialising in Oil Pumps and after-market turbo conversions for road cars.
Wayne served his apprenticeship in the general engineering industry, and then went on to work for Pace Products initially designing, building and installing the specialist automotive turbo conversion kits. During the early 90’s, as the business evolved and expanded, Wayne became one of the directors and was instrumental in developing and building the companies radiator and intercooler heat exchanger core manufacturing facility and business, with the company becoming one of the most recognised names in the Motorsport Engineering industry throughout the 90’s. Alex & Wayne continued to work closely together with ARO Motorsport providing a range of specialist and intricate parts
to support the main production focus of the Pace Products business. As the company expanded its facilities and Heat Exchanger production capabilities Alex continued to work closely with David, Wayne and the team at Pace and was called upon to design and build 2 new CAB furnaces to support the company’s rapid growth and production demands.
PRO ALLOY THE EARLY YEARS
Alex & Wayne had been friends for a number of years, and then in 2002 became brother-in-law’s. Two years later in 2004 they joined forces in business, bringing Wayne’s industry experience and contacts together with the ARO Motorsport business to form Pro Alloy Motorsport Ltd. The company moves from Alex’s small workshop at home in Cambridge to very modest facilities 20 miles to the East of Cambridge in a small, rented unit in Haverhill, Suffolk.
Pro Alloy rapidly gained an enviable reputation for providing a broad range of high-quality Cooling & Fuel System products to the performance tuning industry, attracting interest from a multitude of different business sectors and with much acclaim in numerous magazine articles and TV documentaries and shows.
This demand and growth saw the company quickly outgrow their existing premises and 2 additional units were then occupied – The original facility remained as the company’s engineering and fabrication shop, Unit 2 housed the vehicle installation and product development facility, and Unit 3 became the main office, stores, and packing and dispatch areas.
2009 saw further growth with the company’s move towards design, manufacture and supply of services and products to a number of large commercial organisations and OEM’s, with Pro Alloy being the first choice for supply of intercoolers
direct to the production line at Ford’s production plant in Saarlouis, Germany to support the specialist build programme for the Ford Focus RS500.
With demand continuing to grow for Pro Alloy’s expertise and products, 2010 saw the company move to new and much larger premises, with this new facility enabling all operations of the business to be housed under one roof. Remaining in Haverhill, ensured the skilled and exceptional team were retained, many of which are still with Pro Alloy to this day.
2011 see’s the new Pro Alloy website launched with improved and updated webshop functionality and dealer login portal, which also is linked to the company’s new Facebook pages.
2013 to 2015 presents the business with some unprecedented challenges. December 2013 Pro Alloy’s co-founder Wayne is diagnosed with stage 4 Esophageal Cancer. Despite undergoing extensive cancer treatment over an 18 month period, Wayne sadly lost his battle with the disease in November 2015 – aged 46.
2016 saw some internal restructuring within the business, with Chris Hazell, one of the companies most experienced employee’s, having been with the business since 2004, stepping out of his duties as workshop supervisor and into the role of Technical Sales Manager to support the demands of the company’s busy sales office. Chris remains with the business to this day and is now in the Technical Directors role.
PRO ALLOY TODAY
With business landscape and Automotive industry in particular changing so dramatically over the last 10 years, Pro Alloy’s agility and responsiveness has enabled the business to remain adaptive to the changing marketplace and industry requirements.
With the company’s extensive history, knowledge, and experience of the heat exchanger manufacturing processes, and with heat exchanger cores being one of the company’s key outsourced components, 2018 saw the company expand its manufacturing capabilities by developing its own in-house core production facility. This was aided by the acquisition of Pace Products at the end of 2018, with the transfer across of the heat exchanger core production key staff and equipment into the Pro Alloy HQ in March of 2019. A highly motivated team and efficient implementation into the business enabled the new facility to rapidly become operational, with the first batch of production units passing through the line by the end of April, providing cores directly to our fabrication team to support complete Radiator, Intercooler and Oil Cooler production, as well as providing high quality heat exchanger cores directly to industry.
In a drive to improve, automate and streamline the core production process, much of the original equipment has since been updated and superseded, with investment in new Fin forming machines, CNC punching and material processing machines and equipment. 2023 saw the acquisition of a new LVD CNC punch, which has provided significant improvements in efficiency as well as providing much greater versatility in the range, options and configuration of cores which the team are able to produce.
In addition to the improvements to all of the company’s production divisions, the last 5 years has also seen some radical internal changes delivering significant improvements to all elements of the business.
2020 saw Alex begin working with one of the UK’s leading business mentoring organisations. This shifted Alex’s focus from working ‘in the business’ to ‘on the business’, which has progressively driven change, structure, process, systems and accountability throughout the organisation.
Driving Structure, Leadership and Accountability into the business has helped develop a highly motived and focused leadership team who work closely together to steer and direct all elements of the business fostering a culture of teamwork, performance, and change.
Carl Nunn - Operations Director, Alex Oates - Sales Director, Chris Hazell - Technical Director and Katie Wright in the Accounts and Office Manager role have worked tirelessly to drive significant control, streamlining, systems and process throughout the business which in more recent times has enabled the team to evaluate and re-focus on the organisations primary objectives – to be ‘Performance Driven’ in everything we do and –
‘Provide the Best Products to our Customers, by the Best Team, from the Best Business’
During 2021 the business began the implementation of advanced MRP software which now controls every element of the business, enabling recording, management and reporting data on all of the business activities. Customer enquiries, quotations, production scheduling, recording of production times, purchasing, stock control, time & attendance and final production performance reporting are all dealt with via the software.
MEET OUR TEAM
Alex Osborn
Managing Director
Chris Hazell
Technical Director
Louise Osborn
Marketing Director
Alex Oates
Sales Director
Carl Nunn
Operations Director
Katie Wright
Accounts Office Manager
Sean Smith
Workshop Supervisor
Lee Bayliss
Core Department Supervisor
Hayley Turner
Despatch Supervisor
Max Silvain
Despatch Operator
James Millar
Core Department Operator
Stephen Maddocks
Fabrication Technician
Jack Pope
Fabrication Technician
Stuart Bollen
Fabrication Technician
Liam Mason
Fabrication Technician
Damien Nunn
Fabrication Technician
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Pro Alloy Motorsport Ltd have an unrivalled reputation for outstanding attention to detail, both with our approach to customer service and our rigorous standards of engineering excellence.
With over 40 years of combined experience in the design and manufacture of high-performance alloy components, you can be certain that your requirements will be catered for by a team of passionate and highly skilled fabricators. From fast road applications through to full race team support, Pro Alloy have the experience and expertise to keep you ahead of the competition.
Our alloy radiators, intercoolers and fuel systems are used regularly in the highest levels of motorsport, and our no-compromise approach to quality was born from a desire to exceed expectation at all levels. Our continuous development vision pushes us ever closer towards newer technology and production methods, providing cooling and fuel system solutions in an increasingly diverse industry. Our in-house manufacturing facility gives us full control over our assembly processes, providing us with unmatched flexibility to cater for your needs.
Our proven range of heat exchangers have been put to the test alongside the latest hybrid and electric vehicle technology, and we continue to support research and development projects in military, aeronautical and industrial applications. We have several long-standing relationships with vehicle manufacturers and regularly work alongside powertrain engineers to create and test new technology.
We also offer a thoroughly bespoke fitting service, specialising in low volume, individual creations for all vehicles down to the finest detail. We manufacture components according to customers’ exacting standards, working closely with our clients to offer a truly tailored service. For vintage, classic or modern automobiles, motorcycles and marine craft, even record-breaking world champions, our team will strive to offer the ultimate solution to your requirements.