The production of plastic packaging requires consistent geometry, repeatability between batches and cost control. Replast offers a complete service — from product analysis and mould manufacturing to the mass production of packaging.
We work with manufacturers, distributors and large enterprises, providing mass production of plastic products with predictable costs and the potential for scaling up.
Injection moulding is the ideal solution for packaging when the following factors are critical:
- geometric stability of the product
- consistency in large batches
- production rate
- cost control
What do we offer for packaging production?
- Full production cycle: from product analysis to mass production
- Design and manufacture of moulds
- Optimisation of packaging design (weight reduction, choice of materials)
- Mass production of plastic products
- Statistical Process Control (SPC)
- Technical support for the product
- Production planning based on customer order volumes
What kind of plastic packaging do we manufacture?
Focus: mass-produced items requiring stability and scalability.
- plastic buckets and containers
- technical and household containers (non-food)
- bottle caps
- packaging components
- PET products (injection moulding)
Materials
In the manufacture of plastic packaging, polymers are used that ensure dimensional stability and mechanical strength during mass production.
The choice of material is made on an individual basis, depending on:
- product type
- loads during operation
- requirements regarding rigidity or flexibility
- transport and storage conditions
This helps to reduce material costs and ensure consistent batch quality.
Why is Replast suitable for the production of plastic packaging?
Savings
Reducing production costs through the optimisation of design and manufacturing processes.
Speed
A short production cycle — from test castings to mass production.
Stability
Control of casting parameters and batch consistency with minimal scrap.
Quality
Strict multi-stage quality control in the manufacture of components
Scaling
The ability to increase production volumes without compromising on quality.
Stages of cooperation
- Analysis of a drawing or sample
- Calculation of production costs
- Agreement on the technical specifications
- Design and manufacture of moulds
- Test castings
- Start of mass production
- Long-term supplies
Quality management system
ISO
Process standardisation and quality control
5S
Organisation and discipline in production
Kaizen
Continuous process improvement
SPC
Data-driven parameter control
Case Study: MANUFACTURE OF PLASTIC LIDS FOR HOUSEHOLD CLEANING PRODUCTS
The problem:
- long delivery times (imports)
- currency risks
- inconsistent quality
- product shortages during peak periods
Requirement: 1,000,000+ caps per month
We have proposed launching mass production of lids using the injection moulding process.
It used to be:
- 2.8–3.2 UAH per item (imported)
- 30–45 days delivery
- up to 7% of rejects
- risks of supply disruptions
It has become:
- 1.6 UAH each
- Delivery within 5–10 days
- no defects
- fixed price in UAH
- guaranteed volumes
Savings based on a volume of 1,000,000 units per month: 1,600,000 UAH per month – return on investment in the mould within 0.5 months
What the client received:
- independence from imports
- reliable, uninterrupted supplies
- a 50% reduction in production costs
- quality control (leak-tightness, strength)
- readiness to scale up production
FAQ
What is the minimum order quantity for a packaging run?
Is it possible to optimise the existing packaging?
What is the timeline for starting production?
Do you work with PET?
Do you manufacture food packaging?
Quality certificates
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