Mold Waterway Cleaning Case Studies
How a Beverage Packaging Manufacturer Reduced Production Downtime by 80% with Double-Easy Mold Waterway Cleaning
The customer is a large beverage packaging manufacturer and a core supplier for Great China Holdings.
This application overview discusses mold cleaning for continuous beverage packaging production and the need to limit maintenance interruptions.
Case at a Glance
| Item | Project Information |
|---|---|
| Industry | Beverage packaging |
| Products | Beverage bottles, bottle caps, and other packaging components |
| Customer profile | Core supplier for Great China Holdings |
| Production environment | High-speed continuous production throughout the year |
| Previous cleaning method | Manual mold cleaning |
| Main challenge | Cleaning inefficiency and frequent production stoppages |
| Solution | Multiple Double-Easy Mold Waterway Cleaning Machines |
| Mold disassembly | Not required during cleaning |
| Cleaning time | Approximately 19 minutes per packaging mold |
| Cleaning efficiency | Improved by approximately 72% compared with manual cleaning |
| Operator requirement | One operator |
| Production downtime | Reduced by 80% |
| Product qualification rate | Improved by 10% |
| Reported annual savings | More than RMB 660,000 |
Customer Background
The customer is a large beverage packaging manufacturer and a core supplier for Great China Holdings.
The company specializes in producing beverage bottles, bottle caps, and other packaging components.
Its production operates under high-speed continuous conditions throughout the year. In this environment, mold maintenance efficiency directly affects production continuity and output stability.
For the manufacturer, frequent interruptions for mold cleaning could result in production losses and make it difficult to maintain stable high-volume operations.
The Challenge: Manual Mold Cleaning Could Not Keep Up with Continuous Production
Before introducing the Double-Easy system, the manufacturer relied on manual mold cleaning methods.
Manual cleaning was inefficient and could not meet the requirements of the company's high-speed continuous production environment.
Frequent production stoppages were required for mold cleaning.
The resulting problems included:
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Low mold cleaning efficiency
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Frequent production interruptions
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Cooling inconsistencies
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Surface defects in packaging components
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Production losses
The manufacturer therefore needed a faster and more standardized mold maintenance process that could reduce cleaning-related downtime.
Multiple Double-Easy Mold Waterway Cleaning Machines Introduced
To improve production continuity and reduce downtime losses, the manufacturer introduced multiple Double-Easy Mold Waterway Cleaning Machines.
The machines were used to support efficient and standardized mold maintenance across the manufacturer's production operations.
The Double-Easy system supports online mold waterway cleaning without requiring mold disassembly.
This allowed cleaning tasks to be completed during production intervals, reducing the effect of mold maintenance on the manufacturer's high-speed operations.
Approximately 19 Minutes to Clean One Packaging Mold
One packaging mold could be cleaned in approximately 19 minutes using the Double-Easy system.
For comparison with another production environment, review this beverage-industry mold waterway cleaning case.
Compared with the manufacturer's previous manual cleaning method, cleaning efficiency improved by approximately 72%.
The shorter cleaning process helped reduce the amount of production time lost to mold maintenance.
Because mold disassembly was not required for cleaning, the manufacturer was also able to reduce interruptions associated with its previous cleaning process.
Standardized Cleaning for Different Packaging Molds
The Double-Easy equipment used in the project was equipped with an intelligent control system.
The system automatically adjusts cleaning parameters to suit different types of packaging molds.
This helped the manufacturer establish a more standardized cleaning process across its mold maintenance operations.
Equipment Configuration for Continuous Operation
The equipment operates with high stability and low failure rates.
Key components include products from internationally recognized brands such as:
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Schneider
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Grundfos
These components were used to support reliable operation under continuous production conditions.
The equipment was also designed for straightforward operation.
Only one operator was required to operate the system, helping the manufacturer reduce labor requirements associated with mold cleaning.
Measurable Results
After implementing the Double-Easy Mold Waterway Cleaning Machines, the manufacturer reported measurable improvements.
| Performance Indicator | Reported Result |
|---|---|
| Cleaning time | Approximately 19 minutes per packaging mold |
| Cleaning efficiency | Improved by approximately 72% |
| Production downtime | Reduced by 80% |
| Packaging product qualification rate | Improved by 10% |
| Annual savings in production losses and labor costs | More than RMB 660,000 |
The implementation improved production continuity while reducing cleaning-related downtime and labor requirements.
Key Project Outcomes
The Double-Easy mold waterway cleaning solution helped the manufacturer:
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Replace inefficient manual mold cleaning
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Establish a more standardized mold maintenance process
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Clean mold waterways without mold disassembly
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Complete cleaning during production intervals
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Clean one packaging mold in approximately 19 minutes
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Improve cleaning efficiency by approximately 72%
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Reduce production downtime by 80%
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Improve packaging product qualification rates by 10%
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Operate the cleaning equipment with one operator
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Reduce production-loss and labor costs
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Achieve reported annual savings of more than RMB 660,000
What This Case Demonstrates
This case demonstrates the importance of mold waterway cleaning efficiency in a high-speed continuous production environment.
The manufacturer's previous manual cleaning process required frequent production stoppages and could not meet its continuous-production requirements.
By deploying multiple Double-Easy Mold Waterway Cleaning Machines, the company established a more standardized mold maintenance process that supported online cleaning without mold disassembly.
The reported results show that cleaning efficiency improved by approximately 72%, production downtime decreased by 80%, packaging product qualification rates increased by 10%, and annual savings in production losses and labor costs exceeded RMB 660,000.
Related Product and Application Resources
Review Product information and machine models.
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