Case Study: High-Volume Moulding for a Global Beauty Brand

Client Overview

A leading global beauty brand with a strong presence in over 120 countries. The company specializes in skincare, cosmetics, and personal care products. Their commitment to innovation and quality requires precise, large-scale manufacturing capabilities.

Challenge

As part of a major product launch, the client required:

• High-volume production of custom-designed plastic components for a new line of cosmetic packaging.

• Tight tolerances and consistent aesthetic quality.

• A rapid turnaround time to meet a global distribution schedule.

• Sustainable production practices to align with the brand’s environmental goals.

Objectives

• Manufacture over 10 million injection-moulded parts within a six-month timeline.

• Achieve zero-defect quality standards to meet regulatory and brand requirements.

• Optimize tooling and cycle times to ensure cost-efficiency.

• Integrate sustainable materials without compromising performance.

Solution

Our engineering and manufacturing teams collaborated closely with the client from design to delivery:

1. Collaborative Design & Prototyping

• Worked with the client’s packaging design team to finalize the mould-friendly component design.

• Created 3D prototypes using rapid tooling and verified functionality and appearance.

2. Advanced Tooling & Automation

• Designed and built multi-cavity, high-precision moulds with conformal cooling to reduce cycle times.

• Integrated fully automated robotic handling systems for part ejection, inspection, and packing.

3. High-Speed Production

• Scaled up to 24/7 production using high-performance injection moulding machines.

• Monitored processes using Industry 4.0 technologies to maintain consistent quality and traceability.

4. Sustainable Materials Integration

• Sourced and tested bio-based and PCR (Post-Consumer Recycled) resins.

• Achieved the same visual and mechanical properties as virgin plastics, reducing carbon footprint by 30%.

Results