Project duration: 6 months
Project scope:
- Design and approval of five bottle variants:
- Product application : carbonated soft drinks and non-carbonated fruit drinks
- Manufacturing of 85 moulds across machines with 10, 12, 16, and 22-cavity configurations, deployed across 3 factories in South India
- Coordinated first-mould validation for downstream change-part development, followed by parallel manufacturing and synchronized dispatch
Project Synopsis
The objective of this project was to support a strong regional beverage player’s operations across 3 factories in South India, each running Chinese-make high-speed rotary blowers, across a range of five carbonated and non-carbonated pack sizes. With machines spanning four different cavity configurations — 10, 12, 16, and 22 — and production readiness dependent on multiple linked systems beyond just the blow moulds, the project demanded precise engineering and equally precise timing.
Designing for a Diverse Product Range
- Each of the five bottle designs — spanning carbonated soft drinks and non-carbonated fruit drinks in different volumes — was developed based on product application, preform weight and aesthetics. It was approved individually to meet the customer’s specific requirements for each product line.
- With designs finalised across such a varied range, the project moved into manufacturing with a clear validation-first plan to de-risk the scale of production ahead.
Validation That Unlocked the Customer’s Full Supply Chain
- For each bottle design, we manufactured a single mould first and sent it to the customer for trials and line validation before committing to full-scale production.
- This early validation did more than confirm the mould — it let the customer produce thousands of sample bottles, which they used to develop change parts for their labelling, filling, and conveying systems in parallel.
- Because bottle production and change-part manufacturing needed to run on parallel timelines, getting the first mould right on schedule was critical to keeping the customer’s entire commissioning process on track.
Precision Engineering Across Four Machine Configurations
- Although the moulds shared a similar overall construction across the customer’s machines, each configuration — 10, 12, 16, and 22-cavity — had different mould diameters, locking dimensions and mounting systems.
- Our engineering team accounted for these differences precisely in each mould, ensuring every one of the 85 moulds fit its intended machine exactly, with no adjustment needed on site.
Designing for a Diverse Product Range
- Each of the five bottle designs — spanning carbonated soft drinks and non-carbonated fruit drinks in different volumes — was developed based on product application, preform weight and aesthetics. It was approved individually to meet the customer’s specific requirements for each product line.
- With designs finalised across such a varied range, the project moved into manufacturing with a clear validation-first plan to de-risk the scale of production ahead.
Validation That Unlocked the Customer’s Full Supply Chain
- For each bottle design, we manufactured a single mould first and sent it to the customer for trials and line validation before committing to full-scale production.
- This early validation did more than confirm the mould — it let the customer produce thousands of sample bottles, which they used to develop change parts for their labelling, filling, and conveying systems in parallel.
- Because bottle production and change-part manufacturing needed to run on parallel timelines, getting the first mould right on schedule was critical to keeping the customer’s entire commissioning process on track.
Precision Engineering Across Four Machine Configurations
- Although the moulds shared a similar overall construction across the customer’s machines, each configuration — 10, 12, 16, and 22-cavity — had different mould diameters, locking dimensions and mounting systems.
- Our engineering team accounted for these differences precisely in each mould, ensuring every one of the 85 moulds fit its intended machine exactly, with no adjustment needed on site.
Manufacturing and Dispatch, Timed to Zero Delay
- While the customer used the empty bottles from pilot mould to progress their change-part development, we simultaneously completed manufacturing of the remaining moulds.
- The dispatch schedule was planned so that moulds and the customer’s newly developed change parts would arrive together, ensuring production could start the moment both were in place.
- Over 6 months, the full requirement of 85 moulds was delivered across all 3 factories on this schedule, with no delays on our part — since any slippage would have stalled the customer’s production start.
Awanti Polymoulds Pvt. Ltd. | Pune, India | www.awantipolymoulds.com
