Project duration: 6 months
Project scope:
- Design and approval of bottles across six pack sizes: 200 ml, 250 ml, 300 ml, 500 ml, 1000 ml, and 2000 ml
- Manufacturing of 30+ moulds (200+ cavities) for six high-speed linear blow moulders
- Coordinated first-mould validation with the machine manufacturer, followed by parallel manufacturing and direct-to-site dispatch across 6 locations in India
Project Synopsis
The objective of this project was to support a leading Indian bottled water brand’s rollout of new high-speed linear blow moulders across six locations in India, covering a full range of pack sizes from 200 ml to 2000 ml. With six machines going live at six different sites, and installation outside our scope, the moulds had to be right the first time — there was no room for on-site correction once dispatched.
Bottle Designing and Approvals
- Working in close collaboration with the beverage brand, our design team developed bottle designs across all six pack sizes to meet the customer’s technical and aesthetic requirements.
- Each design was reviewed and approved before manufacturing began, ensuring alignment across all three parties on specifications that would need to hold across every location.
A Validate-First, Scale-Fast Approach
- Given the scale of the rollout — six machines, six locations, 30+ moulds — we prioritised manufacturing one mould per location first and sent it to the machine manufacturer for trials and validation.
- While validation was underway, we manufactured the remaining moulds for each location in parallel, so that once the first mould was cleared, the rest could be dispatched immediately without losing time.
- This approach meant any feedback from the validation trials could be built into the remaining moulds before they left our facility, rather than being discovered after installation.
Precision at Scale, Zero Rework
- The final order came to 30+ moulds — a mix of predominantly 8-cavity and some 4-cavity configurations — totalling over 200 cavities across all six machines.
- Since installation was not in our scope, every mould had to mount and run correctly on the very first attempt at site. Our manufacturing and quality processes were built around this constraint.
- The result was zero defects and zero rejections across the entire order. All six sites received their moulds on schedule and commenced production as planned, with no delays traced back to mould fit or quality.
Awanti Polymoulds Pvt. Ltd. | Pune, India | www.awantipolymoulds.com
