Case study 2

Process optimisation using filling simulation



To develop a unique, well-designed and functional packaging for dressings and sauces for the gastronomy sector. The packaging should have a handle for better handling. This should make handling more reliable and also make accurate dispensing possible.

The injection situation in combination with the required IML decoration proved to be a challenge. The injection points and the hotrunner must be designed so that the complex part can be filled evenly and without air inclusion. At the same time, the mass flow must be controlled in such a way that no reverse injection moulding of the IML labels can occur.




Development of unique, stylish and functional dressing packaging


The geometry and design of the packaging were created using state of the art CAD systems. The handling was then assured and optimised using prototypes.

The quantity and location of the injection points was simulated in different variants using special, sophisticated CAE software (Computer Aided Engineering). In particular, the combination with the IML decoration placed great demands on the chronological course of the melt flow. A combination of position and geometry of the injection points in conjunction with detailed flow aids and suitable hotrunner balancing achieved the desired result.

The findings from the filling simulation were then
transferred to the injection tool.


The sampled items from the injection moulding tools corresponded exactly with the results of the simulation. Process-reliable series production took place right from the start.

Customer benefit

The use of the simulation dramatically reduced the development time and the associated cost. The optimum solution was found and implemented by comparing the different variants.
A high and consistent series production quality was achieved using the controlled melt flow.


  • Process-reliable production thanks to simulation
  • Reduction of the development time
  • High series production quality