Project duration: 6 months (from project initiation to final delivery)
Project scope:
- Precise replacement of mould holders based on the customer’s high-speed rotary blower
- Manufacturing and validation of a pilot set, followed by scaled production of 14+1 sets in total
- Phased delivery in line with the customer’s operational timeline
Project Synopsis
The objective of this project was to replace obsolete mould holders on a France-made rotary blowing line at an MNC beverage major’s factory in North India. The original shell holders had reached end of life and needed urgent, exact-match replacement to keep operations running without disruption. With the customer’s production continuity at stake, the replacement had to be engineered precisely against the original part — not a reinterpretation of it — and delivered fast once validated.
Engineering From the Original Part
- The customer sent us their original mould holders as reference, and our engineering team precisely replicated the design to match the exact specifications of the France-made rotary blowing equipment.
- The part was manufactured in aluminium alloy, and then surface hardened (hard-anodising) to improve the durability and life
- The fitment plates were manufactured in stainless steel grade, and heat treated to increase the resistance to wear and tear
- Given that these were critical running parts on an active production line, there was no margin for deviation — the replacement needed to match the original’s fit and function exactly, down to every dimension.
First-Time-Right Validation
- To de-risk the replacement before committing to full-scale manufacturing, the customer’s initial order was for a single set, which we manufactured and sent for trial on their live line.
- The trial set was validated “first time okay” — running successfully on the first attempt, with no rework or design correction needed.
- This early validation, built entirely on matching the original part with precision, gave the customer the confidence to place their full remaining requirement with us.
Scaling to Full Replacement, on Schedule
- Following successful validation, the customer placed three further orders of 4, 4, and 6 sets, completing the full requirement of 14+1 sets.
- Each order was manufactured and delivered as scheduled, allowing the customer to phase out the remaining end-of-life holders systematically across their rotary blowing line.
- The entire replacement programme — from first engineering reference to final delivery — was completed within 6 months, restoring full operational reliability to a business-critical production line.
