Project duration: 8 months
Project scope:
- Technical and aesthetic design of a common carbonated drink bottle, based on customer inputs on product application, pack size, and preform weight
- Pilot mould manufacturing and rigorous bottle testing as per international standards
- Manufacturing of 80+ moulds across four different rotary blowing machine brands for six franchise-bottling operations
Project Synopsis
The objective of this project was to design a common bottle for different flavours of carbonated drinks and manufacture moulds for six franchise-bottling operations of a global beverage brand in India. This was a full-scale project in every sense — starting with bottle design, moving through unit cavity trials, and ending with commercial mould manufacturing for individual bottlers, each running their own mix of blowing equipment.
Bottle Designing
- Based on customer inputs like product application, pack size, and preform weight, our in-house design engineers used state-of-the-art 3D modelling software to develop multiple design options.
- These options were reviewed with the customer, and one was finalised as the common bottle design to be rolled out across all six franchises.
Pilot Mould Trials
- Since the design was new and the eventual order quantity was large, we manufactured a pilot mould and conducted trials at our own facility before committing to commercial-scale production.
- Bottle samples were tested rigorously against international standards, covering parameters such as section weights, material thickness, base clearance, stress crack resistance, and thermal expansion.
- The final, validated bottle samples were sent to the customer for approval — ensuring the design was fully proven before it was scaled to 80+ moulds.
Mould Manufacturing Across Four Machine Brands
- With the bottle design validated and approved, we manufactured moulds for four different rotary blowing machine brands which were German, Italian and French-make. Each machine requiring 10 to 20 moulds took the total quantity of moulds beyond 80
- Although these machines are similar in operation, mould construction varies meaningfully across brands, and each mould had to be engineered to match its specific equipment precisely.
- Every mould was manufactured accurate to the last micron — the only way these moulds could reliably produce thousands of bottles an hour, for years, with consistent quality across all six franchises.
Awanti Polymoulds Pvt. Ltd. | Pune, India | www.awantipolymoulds.com
