Project duration: 12 weeks
Project scope:
- Design and validation of bottles across the entire pack range, from 200 ml to 3 litres, spanning still water, sparkling water, and carbonated beverages
- Manufacturing of 98 moulds for a French-make high-speed rotary blower with 14 moulding stations
- Supply of critical spares, including stretch rods and stopper pieces, alongside the mould order
Project Synopsis
The objective of this project was to support the launch of a new greenfield factory in Peru for a leading global soft-drinks brand — a company with over 40 years in beverages and a footprint spanning across South America, Africa and Asia. The factory’s French-make high-speed rotary blower, with 14 moulding stations, needed to be equipped for the customer’s entire product range at once: still water, sparkling water, and carbonated beverages across pack sizes from 200 ml to 3 litres. With a new factory’s commissioning timeline riding on this order, design, manufacturing, and logistics all had to move in lockstep.
Two Tracks, Moving in Parallel
- Bottle design and mould engineering were run as two parallel tracks rather than a sequential process, to compress the overall timeline for such a wide pack range.
- Track 1 focused on bottle design: understanding the customer’s requirements, studying their reference drawings, and designing each bottle to its specific volume, product application, and preform weight.
- Track 2 focused on mould engineering: working closely with the customer’s technical team to gather photographs and precise dimensions of cavities, base moulds, and mould parts for the French rotary equipment.
- The two tracks converged once both design and engineering were validated, at which point engineering drawings were released and handed over to production — allowing manufacturing to begin with both product and machine requirements fully locked in.
Built-In Validation Before Production
- Every bottle design was internally validated through unit cavity trials and extensive bottle testing before being carried into full mould engineering.
- This meant that by the time drawings were released to production, the designs had already been proven — reducing the risk of costly rework once 98 moulds were in manufacturing.
Delivering an Entire Product Range, Ready for Day One
- The final scope covered 98 moulds across the customer’s full range of still water, sparkling water, and carbonated beverage pack sizes, from 200 ml to 3 litres, engineered specifically for the 14-station French rotary blower.
- Alongside the moulds, we supplied essential spares — including stretch rods and stopper pieces — ensuring the customer had everything needed to run the line without gaps.
- The complete order was manufactured within 12 weeks, giving the new factory everything required to commission its blowing line for its full intended product range from the outset.
Export Documentation and Compliance, Handled End-to-End
- With a new factory’s commissioning timeline depending on the moulds and spares arriving on schedule, export documentation and customs compliance for shipment to Peru were managed with the same urgency as design and manufacturing.
- Our export team ensured all documentation was accurate and complete well ahead of dispatch, so shipments could clear customs without delays that would have pushed back the factory’s commissioning date.
- This attention to logistics meant the customer could plan their factory start-up date with confidence, knowing that moulds, spares, and paperwork were all moving in sync.
Awanti Polymoulds Pvt. Ltd. | Pune, India | www.awantipolymoulds.com
