Switched a major beverage brand from 24- to 96-cavity closures
Throughput up 4.4×; unit cost down 38%; zero stockouts in following 12 months
Problem. Brand was running 24-cavity closures across 6 sites in Europe. Demand grew 2.3× in 18 months and the supplier could not keep up; outages on a flagship sparkling water SKU cost ~€1.4M in lost sales.
Solution. Built a 96-cavity hot-runner stack mold, validated on a 650 t press with conformal cooling. Took the program from 24-cav 11 s cycle to 96-cav 4 s cycle. 80M units/yr now ships from a single Italian site.