Case Study: TCI Mouldings’ Innovation in Wax Melt Production with Large Silicone Mats
precision silicone moulding technology innovations

Case Study: TCI Mouldings’ Innovation in Wax Melt Production with Large Silicone Mats

13.01.25

Scaling Up: TCI Mouldings’ Large Silicone Mats Revolutionize Wax Melt Production

Introduction

In the booming market of home fragrance, efficiency and scalability are key to meeting consumer demand. A leading wax melt manufacturer sought to enhance their production capabilities to meet growing market needs. TCI Mouldings was tasked with designing and producing large silicone mats that would elevate their production to an industrial standard.

Challenge

The manufacturer needed a solution that would significantly increase their production volume while maintaining high-quality standards. The goal was to create large silicone mats capable of producing hundreds of wax melts in a single batch, optimizing both space and time in the production process.

Solution

TCI Mouldings designed and manufactured custom silicone mats measuring 1.5m by 0.5m, each capable of producing over 700 wax melts per sheet. This innovation transformed the manufacturer’s production capabilities.

Implementation

  • Design and Material Expertise: TCI Mouldings crafted the mats from high-grade silicone, ensuring durability, flexibility, and ease of release, which are crucial for high-volume wax melt production.
  • Precision Engineering: The mats were designed with precise cavities to ensure uniformity in size and shape of each wax melt, maintaining consistent quality across large batches.
  • Scalability: The large size of the mats allowed for significant scalability, enabling the production of thousands of wax melts daily.

Results

  • Increased Production Capacity: The introduction of large silicone mats allowed the manufacturer to scale up to producing thousands of wax melts per day, meeting increased consumer demand.
  • Efficiency and Cost-Effectiveness: The ability to produce over 700 wax melts per sheet reduced production time and labor costs, enhancing overall efficiency.
  • Consistent Quality: The precision-engineered mats ensured each wax melt was of consistent quality, reinforcing the brand’s reputation for excellence.

Conclusion

TCI Mouldings’ development of large silicone mats has revolutionized wax melt production for their client, enabling them to meet industrial standards and market demands. By providing a solution that enhances efficiency, scalability, and quality, TCI Mouldings has demonstrated their ability to drive innovation in manufacturing. This case study highlights their role as a leader in crafting bespoke solutions that support growth and excellence in production.

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