By: Gomathi M -- Research Analyst, Flexible Packaging
03 July, 2019
Rigid packaging products such as caps and bottles are manufactured using injection and blow mold technologies, respectively. Mold sourcing is a complicated process since it is a one-time decision in the lifespan of a mold. Improper mold sourcing and maintenance strategy could lead to losses when the mold fails to last. Both injection and blow molds are classified as Tier 1, Tier 2, and Tier 3 based on cavity and complexity of the mold. The right sourcing option for the right mold tier optimizes mold sourcing and provides cost-saving without compromising on quality. The ideal mold sourcing option also helps to optimize mold maintenance cost involved. This article intends to address the various sourcing strategies available for sourcing low-cost injection and blow molds, for caps and bottles in Europe, along with precautionary measures to be taken for low-cost mold sourcing.
The market for injection and blow molds for caps and bottles was valued at $41 billion in 2017. Europe is the supply hub for technologically advanced molds. The use of high-end technology tends to increase the mold quality and also its price. The mold market in Europe is fragmented by the presence of global and regional players. The strategic sourcing of molds in the region can provide buyers quality molds for reduced prices.
Blow molds are generally classified into three tiers based on the cavity and complexity of the mold. The different mold tiers and its low sourcing strategies are addressed further in this article.
Injection Mold Types
Blow Mold Types
Choice of Mold Material
The choice of mold material depends upon the complexity of mold design, number of cavities, and the required lifespan of the mold. Generally, molds are made of high-grade steel and aluminum. Molds made of high-grade steel tend to last longer than aluminum ones.
Strategy 1: Sourcing of Tier I and Tier II Injection Molds from Regional Suppliers
European regional players from Germany and Italy are equipped with the technologies capable of manufacturing Type I and Type II injection molds. This avoids the dependence of the buyer on a single/global supplier for sourcing Tier I and Tier II molds.
Engaging with regional suppliers for low-cavity molds provides the buyer with higher negotiation power and lowers cost. Regional suppliers are also capable of providing quick prototyping of molds and engage in mold maintenance services.
Some of the potential European regional suppliers capable of producing Tier I and Tier II injection molds are as follows.
Strategy 2: Sourcing of Tier III Injection molds via Central Sourcing
Strategy 3: Sourcing Injection Mold from Integrated Converters
Strategy 4: Sourcing Blow Mold from Mold Manufacturers with Additional Plants in Low-cost Countries
Strategy 1: Sourcing of Low Cavity Blow Molds from Eastern Europe Suppliers
Low cavity molds are mostly used in the extrusion blow molding process. Manufacturing of blow mold is less complicated than injection mold. This makes the cost of blow mold nearly three times lower than that of injection mold. Hence, the suppliers from Eastern Europe are equipped with low cavity blow manufacturing technology.
Sourcing low cavity molds from the Eastern Europe suppliers would give buyers the opportunity to take advantage of the low labor cost in the Eastern Europe Countries. Eastern Europe suppliers, on average, are capable of producing 20-40 molds per annum, hence, sourcing molds from low-volume suppliers of Eastern Europe, bestows buyers with higher buyer power achieved through high volume purchase.
Strategy 2: Combined Sourcing of High Cavity Blow Molds from Large Suppliers
Strategy 3: Sourcing Injection Mold from Integrated Converters
Strategy 4: Sourcing Blow Mold from Mold Manufacturers with Additional Plants in Low-cost Countries
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Choice low-cost mold sourcing strategy depends on the end use requirement of the mold. The execution of low-cost sourcing strategy according to the mold tier type will provide buyers with increased buyer power and provide blanket maintenance contracts that will help the mold to last longer.
The use of proper mold maintenance cycle can also make the mold last longer. Mold maintenance cycle industry norms are mentioned as follows.
Mold Type |
Injection Mold |
Blow Mold |
Tier I |
< 100,000 runs |
60,000 – 80,000 runs |
Tier II |
500,000 – 1,000,000 runs |
300,000 – 500,000 runs |
Tier III |
>1,000,000 runs |
> 500,000 runs |
Implementation of low-cost mold sourcing strategy, along with precautionary steps and practice of mold maintenance cycle in accordance with industry norms will provide buyers with low-cost quality molds that last longer than expected.
https://www.unitedgs.com/resources/five-things-know-your-next-injection-mold/