Delcam’s Power Solution software, plus support from Brazilian reseller SEACAM, helped leading Latin American toolmaker MOLTEC design and manufacture 450 blow mould tools for two and three litre bottles for one of the worldwide leaders in the soft drink market in less than 45 days. Even more impressive was that this delivery time was achieved without affecting any of the company’s other on-going projects.

Based in Santo Amaro, a southern area of the city of São Paulo in Brazil, MOLTEC, which was founded in 1971, manufactures on average 300 blow mould cavities and 200 injection mould cavities per month. This makes it the market leader in Latin America in the manufacture of mould tools for the plastics packaging industry.

According to Managing Director, Mr. Leonardo Arcuri Neto, successes like this recent project are not uncommon in the company’s history. They are achieved thanks to the state-of-the-art technology available in-house, and to its well-trained and committed professional staff.

“During the second half of 2003, we invested US$350,000 in the acquisition of Delcam software to replace our existing 2D software licences within our mould design department,” comments Mr. Arcuri. He claims that MOLTEC is one of the few mould makers in the region with software for 3D design of blow moulds.

The purchase decision was based on a carefully prepared benchmark. “All the global suppliers of software participated,” said Mr. Arcuri. “It took us six months of detailed software presentations and meticulous practical benchmarks to finally take a decision to buy Delcam’s PowerSHAPE.”

Prior to this latest investment, MOLTEC had been using PowerSHAPE and PowerMILL within their Product Design and Manufacturing Departments. “These software tools have been used at MOLTEC for over seven years now. We are able to rapidly develop packaging designs, regardless of the complexity of their shape, as well as generate the best and most optimised machining strategies,” reported Rodrigo Vanni, Design Coordinator. He added that MOLTEC is equipped with the latest HSM machine tools. These guarantee significant productivity gains but, at the same time, require a detailed re-evaluation and fine tuning of the cutting processes so that the expected results can be achieved.

The benefits obtained with the implementation of the new CAD licences are emerging rapidly. “During the first stage, we have already experienced productivity gains within the manufacturing process from 30 to 40%, which should give the return on investment we originally forecast. The extra PowerSHAPE licences guarantee a total process integration from the product conceptual design, prototype production, engineering design, CAM programming, machining and quality control,” confirmed Mr. Vanni. “The three-dimensional visualisation provided during the designing stage practically eliminates mistakes, and the standardisation of components guarantees quality and considerably reduces the designing and CNC programming timings,” he added.