Millions of Mepal containers in four months

11 moulds, 6 machines, 300 fully loaded lorries, ready for sale in 4 months

Some projects have a significant impact on the available space in a factory. This project was no exception, as it required a huge production volume to be achieved within a short timeframe.

Mepal, a long-established Dutch brand specialising in food storage solutions, was looking for a production partner with the capacity to deliver. Within a matter of months, production capacity had to be scaled up to manufacture millions of bowls with lids for a major international retailer.

This required meticulous planning and the rapid implementation of a completely new production line, including six injection moulding machines and the associated automation.

Production line comprising six machines, including three new 500-tonne presses and one new 650-tonne press
11 moulds with 4 and 6 cavities for 4 end products
From order to start of production in four months
Smart layout with in-line assembly and labelling
300 fully loaded lorries delivered within 9 months

Results to be proud of

Scaling up at factory level

The scale of this project required more than just additional production capacity. Within a short space of time, we set up a production area with six new machines, supplemented by four new silos for raw materials, a temporary storage marquee and 2,000 m² of additional storage space. At the same time, dozens of new production staff were recruited and trained.

11 moulds in 7 weeks

This project required 11 large moulds, which in this case were manufactured in China. To ensure these moulds were ready within seven weeks, our teams closely supervised the process and held several on-site coordination meetings. This enabled us to maintain full control over the schedule and progress.

A word is a word

When we took on this project, we knew the timeline was so tight that meeting the deadline was by no means a certainty. But guided by the motto ‘as long as there’s still time, we can still make it’, we pulled out all the stops to meet the requested deadline. It took blood, sweat and tears, but we succeeded. When we set our minds to something, we make it happen.

I want that too

How did we achieve this?

In this project, we brought together all our internal and external resources. Working with project managers and engineers from multiple sites, machinery and automation suppliers, materials suppliers, installation partners and one of our Chinese moulding partners, we delivered an outstanding result. We had to coordinate over 15 different suppliers and partners to ensure that all components were brought together within a short timeframe.

Made in Germany in a sustainable way

Mepal has a reputation to uphold in terms of design and quality, but as a B Corp-certified company, it is also known for its commitment to sustainable products and local manufacturing. Although this project was for a retailer known for its competitive prices, we were still able to manufacture these products in Germany. Thanks to modern machinery, smart automation and optimised logistics, even high-volume projects of this kind are possible in countries where wages are higher

Complexity comes in many forms

In this project, the products themselves were not the biggest challenge. Technically speaking, they were relatively straightforward. However, the complexity of this project lay in the time constraints and the scale.

Which machine supplier can deliver four large new machines within six weeks? Which automation specialist can then immediately install specialised robots? How can we increase our material supply capacity, including new silos, within a few months? Where can we find 30–40 new, partly temporary staff members?

These are the challenges that really get us excited here at De Beer Plastics.

Partnership with De Beer

The collaboration between Mepal and De Beer on this project was quite special, as the stakes were high for both parties. Substantial investment had to be made in machinery and infrastructure within a short timeframe, without any firm guarantees of further contracts after the first year.

That requires trust. And there was plenty of it, on both sides. This meant we could adapt quickly, and where necessary, De Beer Plastics took decisions independently, always putting the project’s interests first. This way of working has only served to strengthen that trust further.

Moulding challenges into Reality