From idea to bottle

The customer order

Some customers, who know exactly how their container will look, supply us with complete layouts. Many others have no concept of the design other than its proposed contents. Still others show us narrow or wide neck containers that they want to produce by means of injection or stretch blow moulding in order to improve product quality. Regardless of the stage of development, conceptual or physical sample, Polymold has the ability to complete your project successfully.

The customer order

Feasibility and design studies

A feasibility study is undertaken to determine whether we are indeed able to produce, with accuracy, the mould for the proposed container and the chosen production process. Alternatively, compromises as to dimension and design will have to be made. In cases where the design of the container (bottle, jar, bellows) is no yet clear, we prepare an engineering study including design proposals.

Feasibility and design studies

Mould concept and quotation

The technical drawing of the mould concept forms the basis for manufacturing the mould. Simultaneously, the technical specifications required for manufacturing the mould are prepared. Following these internal clarifications, we present the technical drawings of the container (bottle, jar, bellows) to the customer, possibly a model, and certainly the most important 3D illustrations and the volume and wall thickness determinations. And of course the costs.

Mould concept and quotation

Preform layout

This step distinguishes us from the majority of competitors, and allows us to demonstrate our know-how. Because only a few tool manufacturers are in a position to determine the layout of the preform. The design and the technical specification of the container to be produced are known.

Preform layout

The test and production tool

It’s now a case of manufacturing either a test tool or the production tool itself. Normally the test tool is manufactured first so that it can be corrected. As soon as the sample containers are perfect, the tool is integrated in the production tools. We normally only manufacture production tools directly if the container moulds are simple or already known.

The test and production tool

Test production

We produce several thousand sample containers in house starting with the test or production tool before it goes into series production at the customer's. This ensures that a container is stable for a given content. In addition to these so called transfer tests, there are filling tests, i.e. the filling machine can be installed and the volume calibrations and timing set. Further more, test marketing can be performed with sample containers and in most urgent cases these very first containers are sold, while the production mould is in the final stage of manufacturing.

Test production

The machine tools

It goes without saying that we are equipped with state-of-the-art IT systems at Polymold. The same applies to the machine tools: CNC drilling and milling work, CNC cutting work, vertical eroding work, cylindrical and flat grinding work.

The machine tools

Production

At this stage the production tool is complete, but work continues. We take care of start-up, optimising the production line at the customer's or the machine manufacturer's premises. We stay with "our container" as long as it takes.

Production

The container

The path from the idea to the completed container is long, and short at the same time.

However, experience, know how and an outstanding technical infrastructure allow us the shortest manufacturing times with the highest perfection.

Quick quotation