SENLAN Precision developed a custom 48-cavity bottle cap mold for S.Pellegrino, a leading European mineral water brand.

The customer’s previous tooling was limiting production performance. The main issues were:

• excessive cycle time
• Inconsistent part weight across cavities
• severe flashing during production

The objective was clear: improve output, stabilize cavity consistency, and reduce scrap in high-volume cap manufacturing.

This project demanded both precision and production stability.

Critical dimensions had to be controlled within 0.005 mm to ensure sealing accuracy and cavity-to-cavity consistency. The mold was designed to run on a Husky injection molding machine, with strict expectations for continuous, high-output performance.

In addition, the mold needed to maintain stable filling behavior, reliable thermal balance, and strong wear resistance under demanding packaging production conditions.

SENLAN Precision addressed the project through three core engineering measures.

A naturally balanced runner layout was developed to ensure all 48 cavities filled simultaneously and under stable pressure conditions. This reduced weight variation and improved process consistency.

The cooling system was redesigned using high thermal conductivity materials in critical areas. This improved heat dissipation, shortened cooling time, and supported a faster production cycle.

All critical mold components were manufactured under strict tolerance control, with key dimensions held within 0.005 mm. Inserts and functional parts were produced with 100% interchangeability, eliminating the need for manual fitting during maintenance or replacement.

Quality assurance was integrated throughout the project.

The mold was verified through:

• incoming material inspection
• in-process dimensional inspection
• assembly verification
• Final CMM measurement of critical components

Measurement records were documented to confirm compliance before delivery.

The new mold delivered measurable production improvements:

• Cycle time reduced from 12s to 9s
• Production efficiency increased by 25%
• Scrap rate reduced from 2% to below 0.1%
• 48-cavity weight deviation controlled within ±0.05g

These results gave the customer a more stable process, lower waste, and higher effective output.

This project demonstrates SENLAN Precision’s capability in high-cavitation cap mold engineering, tight-tolerance manufacturing, and production-oriented mold optimization.

For high-volume packaging applications, mold performance is defined by consistency, cycle efficiency, and long-term stability. This 48-cavity cap mold delivered all three.