'Heavy Metal' team learn to be flexible

Husband-and-wife team Jennie Waterson and Brett Rangitaawa run one of Wellington's last foundries, but the couple are having to adapt fast to survive.

When they started Heavy Metal in 1999, they intended to make moulds and casts for the region's light manufacturing industry.

These days they are moving more into designing their own range of products as local clients move manufacturing overseas to find cheaper labour to stay competitive themselves.

Heavy Metal now employs two product design graduates and is focusing on its own Metalogy range of retro and Bauhaus-inspired metal and acrylic products.

The 800-strong product line includes mirrors, funky, oversized door handles, numbers and letters, sculpture and furniture. The items are sold across New Zealand in architectural supply shops, garden centres and design stores.

The couple started the business after Mr Rangitaawa decided to branch out on his own after 15 years as a foundry moulder. He now runs the foundry.

Ms Waterson, a former florist, clothes designer and administration worker, is in charge of design and running the business.

On the foundry side, Heavy Metal specialises in non-ferrous or sand casting in bronze, aluminium, brass and copper. Last year, it cast the mantle for the Tomb of the Unknown Warrior.

It is working with Weta's head of special effects, Richard Taylor, on casting an eight-metre bronze sculpture -- the Wellington Screen Industry Tribute -- that will stand in Courtenay Place.

Last April, the couple went to DesignEX in Australia to promote the company's Metalogy range, which is now being sold through retailers there.

They are also developing Metalogy's website so the range can be bought on line. The range runs from $17 for a house number to "hundreds of thousands of dollars" for a bespoke piece.

Ms Waterson said the initial investment in a factory site and machinery had been a "huge risk, a six-figure risk" to get started and it had been tough.

As well as the business, the couple have four children aged from 10 months to 15 years old. The couple have a rule that they never work on Sunday and try not to take work home, but Ms Waterson said that could be difficult.

"We've just lost a huge customer to China and more and more of our customers are being forced, to stay competitive, to do the same. So, we are now looking to go niche."

Heavy Metal employs 15 people in the foundry and five staff in administration and design, but the couple are already looking to diversify.

The "next big thing" will be to design and tool-cast in partnership with local manufacturers to make plastic and resin-based furniture.

- NZPA