Client Challenge & Initial Parameters
In 2024, our client from Indonesia provided a Husky HPP4.0 injection molding machine (manufactured in November 2013) with a 112-cavity mold to produce preforms for an aseptic line, requiring internal nitrogen filling (0.3-0.6 bar). The original preform weight was 10.36g. With increasing raw material costs and a drive for sustainable manufacturing by reducing material usage, the client sought a solution to lighten the preform without compromising the bottle's performance integrity.
Husky HPP4.0 injection molding machine
Our Engineered Solution
Our team conducted a comprehensive analysis focused on the mold core system. The solution involved a complete redesign of the mold cores and water cores. This precise re-engineering allowed for the creation of a preform with optimal material distribution, maintaining strength and functionality critical for the aseptic application while achieving a significant reduction in weight.
BJY Engineering Team
Results & Achieved Benefits
The implementation of the new core sets was highly successful:
· Weight Reduction: The preform weight was successfully reduced from 10.36g to 9.36g, a reduction of 1 gram per preform.
· Uncompromised Productivity: The production cycle time remained efficient at 10 seconds per shot.
· Massive Output Scale: Given the 112-cavity setup, the daily output is immense:
· Daily Production: (3600s / 10s) * 24 hours * 112 cavities = 967,680 pieces.
Quantifiable Financial Impact
The financial savings, driven by reduced material consumption, are profound. With a combined raw material and processing cost of CNY 0.01 per gram, the daily and annual savings are as follows:
· Daily Material Savings:
· 967,680 pcs * 1g * CNY 0.01/g = CNY 9,676.80
· (Approximately USD 1,362.93 @ exchange rate 7.1)
· Annual Material Savings (based on 300 operating days):
· USD 1,362.93 * 300 = USD 408,879.00
This project demonstrates that a strategic investment in advanced mold technology can yield an exceptionally fast return on investment (ROI), transforming a per-unit gram saving into nearly $410,000 in annual cost avoidance.
Conclusion
This case is a testament to our commitment to delivering value beyond mere tooling.
By leveraging our design and engineering capabilities, we partner with clients to achieve significant operational efficiencies and cost savings. Lightweighting is a powerful strategy, and its success hinges on precise mold engineering that ensures product quality is upheld. This project exemplifies how innovative mold design is a critical driver for profitability and sustainability in modern PET packaging manufacturing.
