Ali & Fajar Ltd successfully diversify their business in a pandemic with help from the Hub
Earlier in 2020, Muhmmad Ali was in the process of winding up his courier service Ali & Fajar Ltd after five years.
Having sold their vans and submitted a Striking Off Application, he realised that the business could still have a role to play in the context of the COVID-19 pandemic, bringing face mask production closer to home and helping the local community stay safe.
With the help of the GC Business Growth Hub’s manufacturing team, Ali has been able to diversify his business, from working as a courier for the likes of DPD and DHL to becoming a manufacturer, learning along the way about the safety regulations and processes required.
Ali & Fajar now operates out of a business unit in Longsight, producing CE-approved civilian face masks and Type IIR medical face masks, with the ultimate aim of becoming an approved NHS supplier. Recently it received approval from the Medicines and Healthcare products Regulatory Agency for their masks to be used for medical purposes.
Understanding the logistics of setting up a manufacturing business
He admits that none of this would have been possible without the support and guidance he has received from Manufacturing Advisor Martin Hyman: “He’s become essential to my business; I wouldn’t do anything without his advice. He’s a star and this whole journey for me has been possible thanks to him.”
One of Ali’s first challenges was understanding the complexities of the regulatory issues around producing face masks, and Martin was able to help him get up to speed with manufacturing in the COVID-19 landscape.
He also advised Ali & Fajar on the practicalities of setting up their production facility and how to prepare for scaling up their manufacturing processes to cope with the anticipated rise in orders as the business grows over the next few months.
Securing grant funding from the Manufacturing Growth Fund
A key area of growth was identified as the production of the Type IIR mask and the requirement for staff (and their clothing) to be kept clean of infection, which would therefore mean that Ali & Fajar would need to install a full-body disinfection sterilising channel facility.
This will be where their staff will have a temperature check before entering an enclosed channel to undergo disinfection and sanitising procedures, before entering the production area of the factory. The Hub has agreed to provide a capital grant through the Manufacturing Growth Fund towards the cost of the sterilising channel, assisting Ali to submit the application for the Grant.
Ali & Fajar currently has the capacity to produce more than 50 million high-grade masks per year and are starting to see a rise in new clients. This includes one business that was referred to them through Account Manager Deirdre Hughes, who had run the initial diagnostic with Ali after he first contacted the Hub.
Ali credits the speed of his diversification from a courier service to a mask manufacturer to the help he has received from the Hub’s advisors.
It wouldn’t have been possible for me to be where I am now without the help of GC Business Growth Hub, it would have taken me at least another year to be here.
Their help and advice have made this journey really quick for me, and tasks that I thought would take me three or four months to complete have taken one month because of them.
Muhammad Ali, Owner, Ali & Fajar
For more advice on business recovery, visit our COVID-19 manufacturing guidance page or book an appointment with one of our specialist Manufacturing Advisors via ManufacturingOperationsTeam@growthco.uk
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