Case study · manufacturing
A vegan brand's cheese wheel mould.
A cavity mould for a labelled retail SKU, cavity volume set around fill density to hit the labelled weight.
Customer
A vegan food brand
A UK vegan food brand producing plant-based cheese wheels needed cavity tooling for their flagship SKU. The wheel had a labelled net weight, so cavity volume had to be calibrated around the fill density to hit that weight reliably. They also wanted the underside of the wheel embossed with the brand logo.
The challenge
What we had to solve.
The fill was a plant-based mixture with a density that varied slightly by production batch. Cavity volume had to be set so that the average batch hit target weight, with allowance for the range of density they normally saw. Underside logo had to read but not so deep that it caused packaging problems.
The approach
What we did.
We worked with the brand's production team to characterise fill density across three batches and set cavity volume from the average. Logo depth was calibrated to be readable on the finished wheel but shallow enough to not affect wrap. Grade was standard food-contact silicone, dishwasher-tolerant.
Outcome
How it works now.
Wheels consistently hit labelled weight within the brand's tolerance. The brand reorders trays on rolling replacement schedule and adds cavity trays as they scale.
Details
The specifics on this build.
Product
Retail vegan cheese wheel with underside brand emboss.
Route
Hand-poured food-contact silicone, cavity volume calibrated to fill density.
Grade
Standard food-contact platinum-cure silicone.
Cleandown
Commercial dishwasher, production standard wash cycle.
Related services
How this fits our capability.
Portion control moulds for consistent yield
Branded cavities that read on the finished product
Scaling from bench pour to production tooling
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