Ewan Lake and Tufcoat: From side hustle to nationwide business 

Ewan Lake and Tufcoat: From side
hustle to nationwide business 

It is perhaps fitting that an entrepreneur by the name of Ewan Lake would make his breakthrough in the world of boating.

However, it would be wrong to suggest it was written in the stars.

Ewan’s early career was steeped in tech and the military. He studied Computer Systems at Coventry University between 1993 and 1999, during which time he spent several years as a Telecommunications Technician in the British Army, serving under NATO in the former Yugoslavia.

Upon graduating, he joined the corporate world as an Applications Engineer for BAE Systems, moving into a team which specialised in applying elements of military technologies to the commercial market.

Back then, few, including Ewan himself, would have predicted that he would go on to build the UK’s leading supplier of shrink-wrap materials and installations.

It was a dramatic departure from his professional life to date, and it was 2004 which proved to be the crucial period when the stars started to realign.

Let’s pick up the story with Ewan from here.

What prompted the decision to set up your own business with your founding partner?

We worked together in the commercial sales team at BAE, but didn’t really fit into the corporate culture. Every tea break, we’d sit there dreaming up ways to break free and do our own thing. Our colleagues even nicknamed us ‘The Escape Committee’!

Our roles involved a lot of travel, especially to the US, and during one of those trips we came across a boatyard full of shrink-wrapping boats. We hadn’t seen anything like this before and couldn’t find any good reasons why it wouldn’t work in the UK.

So, we did our research, found a company called Dr Shrink that supplied the shrink-wrap materials, and imported some to wrap a boat ourselves and learn the ropes. Once we saw the potential, I gladly accepted the voluntary redundancy package BAE offered and fully invested into the new venture, which we called Boatcoat.

When did you realise you had a serious business on your hands?

We lived something of a roady lifestyle to begin with, venturing across the country to see what demand there was for shrink-wrap boats.

It was when we spoke to a boat yard in North Wales that things really started to change. We were told that Airbus, not far away in Chester, had been in contact with the boat yard about wrapping services. They were spending around £250,000 a time on supposedly reusable traditional covers which often got damaged or lost, and had to keep being repaired & replaced so they needed to find something better.

It was a massive moment. We gave Airbus a free shrink-wrap demonstration using our last rolls of imported Dr Shrink material – this marked the beginning of a 15-year contract.

How has the business evolved since?

Two big developments have defined our journey – the move into construction and the expansion of our value proposition to include product installation.

The financial crash in 2008 prompted the building industry to come to a standstill. A lot of projects hit the pause button, creating a huge demand for shrink-wrap to protect sites.

We also found that, at sites which were still working, there was a need for advanced encapsulation and containment on large structures to protect the environment around building sites from dust and debris generated by the work. At the same time, the sheets helped to improve the appearance of construction sites under development.

This led to our rebranding to Tufcoat. While we still wrap boats, our main line of business now comes from the building sector.

By 2010 we were growing fast. We had already hired a local firm to warehouse our stock and made more hires across admin, sales and marketing.

Focussing on getting the most efficient outcomes for our customers has meant evolving into both a supply only and an installation business, which is arguably the most significant business decision Tufcoat has made. The installation service comprises mobile teams who are on the road installing shrinkwrap on customers’ sites and assets – adding this string to our bow was a game-changer.

How would you describe your approach to running Tufcoat?

It was crucial for me to build a family-oriented and relaxed culture at Tufcoat. I’ve tried to instil an environment where employees have a comfortable work–life balance while still working hard, pitching in and being flexible. For me, it is about ensuring that flexibility works both ways for the employee and the company – everyone benefits.

Over time, I’ve learned that drawing on the expertise of others is key to overcoming challenges. I rely heavily on the input and skills of key staff like Barry Kirkham and Kieran Walsh, who work together guiding the day-to-day operations. This allows me to focus on the innovation and growth that will future-proof the business.

We’re still a relatively small fish in a pond of huge multi-faceted players. When our teams work on high-profile projects such as the Houses of Parliament and Buckingham Palace, it instils great pride and is hugely rewarding for all involved. I never want to lose that buzz.

What are some of the recent challenges and opportunities the business has faced?

When it comes to industry challenges, I’d have to point to Brexit as having a major impact on Tufcoat. We lost our entire European business as a result. Likewise, major national events like a general election tend to bring projects to a standstill. The key is to remain positive – I always reassure our staff and clients that I’ve seen it before and everything will turn out OK.

Looking ahead, the growing UK film industry, with its associated tax incentives, is having a really positive impact on our reach, especially as black wrap becomes more regularly used. Our team has even spent time on the set of the film Dune in Jordan, and we’ve provided shrink-wrap for Star Wars including on the Millennium Falcon and cars in the Fast and Furious films.

How important is environmental responsibility to Tufcoat?

I knew that achieving ISO 14001 certification for Environmental Management was essential for our sustainability ambitions, as well as maintaining a laser-like focus on compliance with legislation and reducing waste.

Our shrink-wrap can be recycled into other plastic products. I’ve always been keen to educate our customers on this element of our business, which is a service we’re happy to handle for them.

We’ve also developed our manufacturing process to be as sustainable as possible, although the plastic element will always be instrumental in delivering the performance our shrink-wrap needs. That said, I’m committed to exploring how we can achieve that same level of weather protection without using plastic materials.

I’m also actively looking at avenues where we can take back used shrink-wrap from customers and recycle it ourselves into new products here at Tufcoat. Closing that loop is a big priority for me in reducing our environmental impact.

Tufcoat celebrates 20 years this year. What lies ahead?

First and foremost, we need to celebrate this milestone with a big summer party. As I reflect on the challenges and rewards, I’m really positive about our future growth through expanding our successful regional team model. Building off what we’ve done in Sheffield, Northampton, Bristol and Plymouth, I want to collaborate with more local manufacturers so our installers can be home nightly, and customers get a localised service.

It will be a busy time balancing the party, family life, customer support and positioning ourselves for continued growth through regionalisation. But it’s a challenge I’m looking forward to.

Finally, tell us a bit about the person behind the business.

My life outside of Tufcoat revolves around my family. I have three kids – Anna is studying at university, Nathan is at sixth form, and Aidan, my youngest, is 15.

When I can find the time, I enjoy playing guitar and spending days out on my boat, though that doesn’t happen as often as I’d like these days. I’m also a former sub 3-hr marathon runner and even have a couple of 100-mile running events under my belt.

So in between running the business and being a dad, I try to squeeze in my hobbies and athletic pursuits when possible. It’s all about striving for that balanced life – though as anyone running their own business would admit, that’s often easier said than done!