Custom Moulding A Unique Journey to Your Own Packaging

At Frapak, we believe that packaging is more than just a container. It serves as an extension of your brand identity, a communication tool, and a way to protect your product. While a standard packaging solution might suffice in some cases, custom moulding is the ideal choice when you want to stand out or meet specific requirements. With this approach, we work together to create a bespoke packaging solution that perfectly aligns with your needs. Below, we outline the 10 detailed steps we follow to ensure every detail is just right.

Customer’s Idea or Concept

Every journey starts with an idea or concept. Perhaps you already have a clear vision of how the packaging should look, or maybe you only have a rough sketch in mind. In both cases, we are here to help you refine your vision. Whether you need a striking bottle for a new cosmetics line or a functional, minimalist jar for a food product, share your ideas with us, and we will help you develop them further.

Why Is This Step Important?

1. It lays the foundation for all subsequent steps in the project.
2. It helps us better understand your brand and map out any specific needs or requirements.

Co-Creation with Your Brand

If your concept isn’t fully developed or you’re looking for inspiration to make it truly unique, we initiate a co-creation process. During this phase, our packaging experts work closely with you to optimise the shape, style, and technical feasibility of your packaging. Together, we focus on:

• Branding and Design: Does the design reflect the desired brand identity?
• Practical Considerations: Is the design suitable for your target audience’s usage needs?
• Innovation: Can new techniques or materials elevate your packaging to the next level?

With our experience across various industries from cosmetics and pharmaceuticals to food products we understand the choices that make a difference. The result? Packaging that not only looks exceptional but is also perfectly functional and aligned with your needs.

Feasibility and Technical Requirements

Once the concept begins to take shape, we conduct a thorough analysis of its technical feasibility. This involves evaluating your design based on:

• Leak Resistance: With our testing methods and years of experience, we ensure bottles and jars are developed to prevent leaks effectively.
• Closures and Caps: We verify that the packaging is compatible with the desired closure whether a pump, spray, or screw cap while ensuring optimal functionality.
• Filling Line and Production Machines: The design must seamlessly integrate with your (or a third party’s) production line. This includes ensuring the shape, dimensions, and balance align perfectly with filling and labelling machines.
• Decoration and Labelling: We assess whether the shape and material are suitable for the desired decoration techniques or labels, such as screen printing, hot stamping, offset printing, or adhesive labels.
• Colour and Material: Often, specific colours or effects (e.g., matte, glossy, transparent) are required. We also consider additives to enhance durability, UV protection, or barrier properties.

This meticulous evaluation prevents unforeseen issues later in the process and lays a solid foundation for a smooth development journey.

From Concept to Digital Design

Once the requirements and feasibility are clear, we transform all insights into a technical design using SolidWorks, advanced 3D modelling software. This allows us to create a highly detailed representation of your packaging, giving you a clear understanding of:

• Dimensions: Height, diameter, wall thickness, and any structural elements.
• Design Features: Curves, angles, ergonomic grips, or other specific details.

This digital model serves as the blueprint for the final product. You’ll have the opportunity to review the design in detail, provide feedback, and request adjustments as needed, ensuring the result aligns perfectly with your vision.

3D Mock-Up and Optimisation

Once the digital design is approved, we bring it to life with a 3D mock-up. Using our in-house 3D printers, we create a physical prototype of the bottle or jar, allowing you to hold the design in your hands. This tangible model helps to:

• Evaluate Ergonomics and Grip: Does the packaging feel comfortable to hold? Is the opening sufficiently sized?
• Check Visual Aspects: Do the proportions and contours align with your brand image?
• Gather Practical Feedback: Does the cap, spray head, or closure fit perfectly on the mock-up?

At this stage, any necessary adjustments can be made quickly and efficiently. The design is revised and tested until you’re completely satisfied. Only then do we move on to the next step.

Developing the Production Mould

With the design finalised, we manufacture the production mould (master mould) in our facility. This is a meticulous process, as every detail from the smallest angles to the thickness of the bottle walls must be precisely accurate. The production mould forms the foundation for reliable and consistent mass production of your unique packaging.

Initial Production Run and Colour Matching

Before moving to full-scale production, we conduct an initial production run (pilot series). This test phase ensures that:

• Quality and Consistency are Verified: Are all bottles or jars identical and in line with the agreed specifications?
• Colours are Matched Accurately: If you require a specific colour, we perform detailed colour matching under various lighting conditions (e.g., daylight, retail lighting). This step ensures your packaging achieves the precise look you envision.
• Material Choices are Validated: We assess whether the selected material meets all requirements, including durability, barrier performance, and aesthetic appeal.

At this stage, adjustments can still be made, ensuring a smooth and flawless final production process.

Decoration and Printing

With your packaging fully approved on a technical level, the focus shifts to its visual appeal. Beyond its shape and colour, you can choose from a range of advanced decoration techniques:

• Screen Printing: Ideal for cylindrical surfaces, allowing 360-degree designs to enhance your brand.
• Foil Stamping: Creates a luxurious effect with metallic foils in gold, silver, or other finishes.
• Offset Printing: Perfect for sharp, vibrant prints on larger surfaces.

These decoration options elevate your brand presence and make your packaging stand out on the shelf.

Logistical Coordination and Delivery

A successful project requires a seamless supply chain. That’s why we carefully address logistical details throughout the entire process:

• Packaging Volumes: How many units per pallet, in what boxes, and with which packaging configurations?
• Delivery Times: When do you need the packaging, and how can we align our schedule with your requirements?
• Transport and Storage: Should we deliver everything at once, or opt for partial deliveries to help you manage inventory more efficiently?

By discussing these aspects clearly and in advance, we ensure a smooth delivery process without unnecessary delays or storage challenges.

A Successful Final Outcome

Ultimately, the goal is to provide packaging that perfectly reflects your brand and meets all technical requirements. At Frapak, we are committed to elevating your product and leaving a lasting impression on your customers.

The majority of our custom moulding clients return for new projects because we prioritise quality, innovation, and customer satisfaction. This often leads to long-term partnerships where we collaborate on new packaging challenges and continue to push boundaries together.