Last year, Raybloc (X-Ray Protection), which is based in Willenhall in the West Midlands, marked the passing of 25 years since its foundation. Established in 1999, the family-owned business is now run by the third generation that still strives towards the vision of being the leading innovator in changing the face of radiation shielding worldwide. The company’s strong foundation is woven in the threads of hard work and passion. From a humble beginning, operating from a small garage in Willenhall, to a massive manufacturing facility in the same town, the company has come a long way. Our journey is a testament to unwavering dedication, visionary leadership, and a relentless drive for excellence, that have raised the bar of radiation shielding products, and that will further prepare them for the future.
A legacy of innovation
Raybloc’s story began in 1999, when Project manager, Sean Haydon, and Chief carpenter, Leonard ‘Len’ Street, decided to address a gap in the market for high-quality radiation shielding solutions. Sean was then working as a Project manager at Wolverson X-Ray, where he first identified a need for a reliable X-ray screen. With Len’s expertise in carpentry and engineering, the pair set out to design a solution that would meet the high standards of the healthcare industry. “We wanted to offer more than just a product; our aim was also to offer peace of mind,” Sean Haydon recalls.
Their breakthrough came when they developed a high-quality X-ray screen, undertook an in-house photo shoot, and secured coverage for it in Rad Magazine (a specialist medical imaging title read by radiologists, radiotherapists, radiographers, and medical imaging specialists). The publication featured their product, and — soon afterwards — a representative from Philips contacted them to ask about the screen. By offering a shorter lead time for such a product — four weeks, compared with the usual eight, they secured a significant order from the multinational.
Raybloc’s early success was largely attributable to its commitment to quality and willingness to ‘go the extra mile’. Some competitors charged for alterations such as colour upgrades, but with its ‘customer and end-user first’ service ethos, Raybloc offered bespoke design and options at no extra cost, helping further differentiate it in a competitive market. This commitment to precision and customer satisfaction quickly led to a growing demand, and Raybloc was soon established as a trusted name in radiation shielding.
The core values instilled by Len Street and Sean Haydon, Raybloc’s founders, are at the heart of the business’s success, and continue to shape our business practices. For example, proactivity is ingrained in our daily operations. A prime example was during a recent project when an unexpected delay in the client’s site preparation threatened to push back the completion timeline. Rather than waiting for the issue to be resolved, our team adapted our schedule, working extended hours, and coordinating with on-site teams to ensure the project stayed on track. Additionally, when a last-minute specification change required a custom-sized Sense-X window, we expedited the manufacturing process to meet the deadline without compromising quality. This commitment to proactive problem-solving not only maintained project efficiency, but also reinforced our reputation for reliability and exceptional customer service.
Maintaining knowledge
Continuous improvement is key to Raybloc’s success, and our team is our committed to keeping up to date with the latest advancements in radiation shielding technology — whether by attending conferences, undertaking specialised training, or participating in knowledge-sharing sessions. Thus when a client comes to us with a complex shielding requirement, we don’t simply offer a standard solution; rather we apply our collective expertise to provide the most effective, innovative answer. For instance, our in-depth knowledge of lead equivalency allowed us to optimise the design of a recent installation, reducing material usage without compromising on safety.
Clear and honest communication is fundamental to how we operate. During a recent hospital project, an unexpected site constraint meant that our originally specified doorset dimensions wouldn’t fit. Instead of delaying the project, we immediately informed the client, worked closely with its team, and quickly revised the design. By maintaining transparent communication, we prevented costly delays, and ensured that the project stayed on schedule.
Accuracy is critical in radiation shielding — something exemplified in our recent manufacture of a set of custom Sense-X windows for a high-profile diagnostic centre. Given the strict requirements for lead lining, transparency, and switchable technology integration, even the slightest miscalculation could have led to significant performance issues. By meticulously double-checking every measurement, conducting rigorous quality control checks, and using precision engineering, we ensured that the final product was flawless, and met all regulatory standards.
Enthusiasm
Passion drives everything we do at Raybloc, and this is reflected in the way we approach each project. A great example was during our work in a paediatric radiology department, where we collaborated with the client to develop shielding solutions that not only met safety standards, but also created a more welcoming environment for young patients. Our team eagerly explored creative design options, incorporating vibrant colours and custom finishes to make the space feel less clinical. Our enthusiasm for making a difference ensured that the project was a resounding success, improving both safety and patient experience.
Raybloc’s journey has not been without its challenges. In the early years, the company struggled to secure high-quality materials, and faced difficulties in managing operations with a small team. Sean Haydon and Len Street worked day and night in a small place while two of Sean’s friends handled late-night installations. One particular challenge was the labour-intensive process of assembling X-ray screens using screws, but undeterred, the team saw an opportunity to innovate and streamline production. Through hard work and perseverance, Raybloc overcame these obstacles, and the company’s commitment to excellence only strengthened.
Milestones in the journey
Throughout the past 25 years, Raybloc has achieved a number of key milestones that have been crucial to its success. In particular, the business has secured multiple contracts with the NHS, cementing its reputation as a trusted supplier of radiation shielding products, while in its first five years in operation, the company established collaborations with global companies such as Philips and GE, expanding its reach and credibility.
In 2022, to accommodate growing demand, we built a new state-of-the-art manufacturing facility, in Willenhall, and in 2024 worked with Fujifim UK to deliver a ‘cutting-edge’ X-ray showroom at the latter’s Bedford facility.
Participation in industry trade shows, such as Healthcare Estates 2024, has enabled Raybloc to showcase its solutions to a broader audience. One particularly significant new product launch, in 2024, saw us unveil Sense-X, a ground-breaking advance in radiation shielding technology designed to meet the evolving needs of modern medical imaging environments. The Sense-X range comprises two solutions:
- Sense-X Screen: A lead-lined X-ray screen with a sleek, frameless glass finish and customisable LED lighting for enhanced visibility and aesthetics.
- Sense-X Internal Window: A PVC-encapsulated radiation shielding window, also featuring customisable LED lighting for added functionality and ambience.
Developed with input from patients, radiographers, and Radiation Protection Advisers, Sense-X prioritises safety, efficiency, and patient comfort, in radiation-exposed environments. Going beyond traditional shielding, it has a sleek, modern design, and is designed to foster a calming atmosphere — by reducing patient anxiety and enhancing workplace wellbeing for radiology staff.
Raybloc’s culture is rooted in the values established by its founders, with a sense of belonging and mutual respect fostering a collaborative environment, where employees are encouraged to innovate and contribute to the company’s continued success.
The Haydon family’s commitment to the business is evident in their day-to-day operations, as they lead by example, and inspire the team to strive for excellence.
Raybloc has consistently been at the forefront of developing cutting-edge radiation shielding solutions. Over the years, our product range has expanded, to include:
- Lead-lined doors: Known for their durability, precision, and ease of installation, and providing the highest level of radiation safety, tested by physicists for over two decades.
- X-Ray screens: Designed to ensure both protection and clarity, Raybloc X-ray screens are trusted by healthcare facilities worldwide.
- Bespoke shielding installations.
- Lead-lined boards: Raybloc supplies and installs lead-lined boards, plasterboards, and lead-lined plywood designed for maximum X-ray protection. These come in a standard thickness of 12.5 mm (excluding lead thickness), and provide a complete shielding solution for scanning rooms, ensuring 100 per cent X-ray protection.
Each product is meticulously crafted, combining innovation with the highest standards of quality control to ensure long-lasting reliability.
David Gatenby, Operations manager at Raybloc, says: “I joined Raybloc nine years ago as part of the Sales team before developing into my current role. My focus is always on reducing lead times, constantly refining processes, and ensuring that our on-time delivery rate stays above 95%. Together, we’re not just improving processes; we’re growing a business that people are proud to be part of.”
What sets Raybloc apart?
Raybloc’s success is driven by several key factors, including a customer-centric approach, with every product tailored to the client’s needs, precision-crafted, and undergoing rigorous testing to exceed industry standards. The company prides itself on offering exceptional support throughout the entire lifecycle of our products, from initial inquiry to post-installation. Our pre-hung doors simplify installation, saving contractors time and money, and are guaranteed to last and result in zero room downtime, giving full peace of mind that the room is 100% radiation safe.
Raybloc’s products have had a significant impact on healthcare environments. Our Flush-Mounted Warning Lights, for example, are linked to X-ray or CT scan machines, alerting anyone outside the radiation area when the machine is in use, and thus significantly reducing exposure risks. The innovative Sense-X technology not only provides superior radiation protection, but also enhances patient comfort and reduces anxiety. Knowing our products play a role in saving lives and supporting healthcare staff is the most rewarding aspect of our work.
A commitment to sustainability
Raybloc is committed to promoting environmental sustainability, and, for instance:
- Sources lead from 100% recycled material.
- Recycles over 95% of lead, with none going to landfill.
- Uses energy-efficient processes, such as recycling lead, which has a lower melting point.
- Utilising FSC-certified timber, and powering our manufacturing unit with a biomass plant to reduce carbon emissions.
Looking to the future with a 5-Year Plan
As we celebrate 25 years, Raybloc is already focused on the future. Our strategy for the next five years includes:
- Global expansion: We plan to increase our international presence, working closely with healthcare providers and industry experts worldwide.
- Sustainability: We will continue to explore new materials and practices to reduce our environmental footprint.
- Digital transformation: We are investing in digital tools to improve our operations, customer engagement, and product innovation.
- Product innovation: We plan to continue to patent new products and leverage cutting-edge technologies to further improve the end-user experience.
- Knowledge-sharing: From delivering lectures at universities. to collaborating with professors and academics, we are committed to raising awareness about radiation shielding, and advancing developments that are at the forefront of the industry.
- Thought leadership: We are working on generating white papers, securing mentions in academic journals, and engaging in global collaborations to solidify our role as a trusted authority in radiation shielding, and help others make the best and safest decisions around radiation safety.
Innovation, dedication, and excellence
Raybloc’s 25-year journey has been one of innovation, dedication, and excellence. As we look to the future, we are committed to continuing our legacy of providing the highest-quality radiation shielding solutions, supporting the healthcare industry, and expanding our reach to more industries for many years to come.
“We’re deeply grateful to all our partners, customers, and most of all, our employees, who have been part of our story, as it is putting the people first that has got us to where we are today,” says Lewis Haydon, director at Raybloc. “Here’s to the next 25 years of growth, innovation, and making a difference.”
Having looked at how Raybloc started out, before building a reputation for innovation and quality, as well as having focused on some of the developments and milestones in the past quarter century, let us now spotlight two examples of our technology in action.
Case study1: Fujifilm, Bedford
In late 2024 Raybloc created a state-of-the-art X-ray showroom within Fujifilm’s new facility in Bedford, where the marriage of custom-crafted lead-lined doorsets, frameless X-ray screens, and a visionary design philosophy, re-shaped the very essence of radiology spaces.
The specifications for this project were exacting, necessitating the use of oak timber frames for the lead-lined doorsets, and laminate surfaces to ensure durability and visual appeal, with the addition of exclusive flush-mounted warning lights for a sleek and hygienic touch to a required feature for any controlled area.
The frameless X-ray screen was designed to offer unobstructed visibility while adhering to stringent safety standards. The solutions had to be seamlessly integrated into the facility’s architecture, balancing the functional requirements of radiation protection with the aesthetics of a modern medical facility.
The challenge
When Raybloc was presented with the opportunity to contribute to Fujifilm UK’s new facility in Bedford, the challenge was clear: to develop and manufacture radiation protection solutions that merged cutting-edge technology, innovative design, and optimal functionality. The objective was to create an X-ray showroom that not only met stringent safety requirements, but also provided an environment of comfort and convenience for both radiographers and patients.
Raybloc’s collaboration with Fuji Corporation marked a milestone in the installation of custom-designed radiation protection solutions. The process involved a meticulous integration of various components, including oak timber-framed lead-lined doorsets with laminate faces, and the incorporation of a state-of-the-art frameless X-ray screen. The expertise of Apollo Building Services and MCS Building Services in installing the Frameless Operator Screen and Radiation-Protective Doorsets respectively ensured that the solutions were seamlessly integrated into the facility’s infrastructure.
Raybloc’s solution involved the creation of radiation-shielding elements that harmoniously blended functionality and aesthetics. The Lead-Lined Doorsets, equipped with flush-mounted warning lights, provided an additional layer of safety. The introduction of the Frameless X-ray screen reimagined the traditional X-ray room layout, enabling enhanced communication and ease of movement for radiographers, while maintaining the required level of protection. This holistic approach to radiation protection transformed the X-ray showroom into a model of modern design and safety.
Case study 2: Wimpole Street Diagnostic Centre, London
Here Raybloc developed a ‘next-generation’ CT scanning room for Apollo Building Services’ project on behalf of Siemens Healthineers at the Wimpole Street Diagnostic Centre, in the heart of London. The project involved the manufacture and installation of custom-crafted lead-lined laminate Raybloc Doorsets, and what we believe are the world’s first anxiety-reducing Sense-X internal windows.
The project had highly specific requirements, particularly as regards the dimensions involved. The windows needed to be larger and wider to enhance the radiographer’s view and allow additional natural light into the room. The client also required flush-mounted warning lights on the door to alert those outside about the presence of radiation when a procedure was in progress.
To ensure durability and visual appeal, lead-lined doorsets with a laminate finish were specified. Additionally, a specialist double Sense-X Internal Window was designed to optimise lighting while maintaining stringent safety standards.
Challenges faced
One of the major challenges was the development of a specialist window comprising two Sense-X windows fused together. These needed to be manufactured to precise dimensions with clearly defined viewable areas, as LCD switchable film was to be retrofitted later by the client. To ensure accuracy, Raybloc provided detailed drawings of the window, along with lead detail specifications for the Radiation Protection Advisor (RPA).
Additionally, the custom window was required on a very tight deadline during the holiday period. Despite the Christmas break, Raybloc successfully delivered the window on 27 December, outside of normal working hours, to align with Apollo’s project schedule.
The project was completed in two phases: Raybloc’s collaboration with Wimpole Diagnostic Centre marked a significant milestone in the installation of tailored radiation protection solutions. The process required meticulous integration of various components, including lead-lined laminate doorsets and next-generation mood-enhancing windows. Apollo Building Services’ expertise ensured that these solutions were seamlessly incorporated into the facility’s infrastructure, reinforcing both functionality and safety.
The project highlights Raybloc’s ability to adapt to unique requirements, work under challenging conditions, and provide industry-leading solutions that enhance safety, efficiency, and design, in medical environments. As we continue to push the boundaries of innovation, Raybloc remains a trusted partner in advancing radiation shielding technology for healthcare facilities worldwide.