Custom Mold Development & Custom Packaging Solutions
From the first packaging concept through engineering, tooling, sampling, production and commercialization, Empire EMCO helps manufacturers develop custom rigid packaging solutions around real product, production and supply-chain requirements.
A custom package can create a shape, feature, closure, dispensing system or structural solution that is not available through existing stock packaging. But developing a custom mold involves much more than creating tooling. The package must be designed for manufacturability, evaluated for the intended application, sampled, approved and successfully moved into commercial production.
Empire EMCO brings packaging design, engineering, sourcing, manufacturing coordination and commercialization support together to help manage that process from beginning to end.
When Does Custom Packaging Make Sense?
Not every packaging project requires new tooling. Custom development becomes valuable when an existing package cannot adequately address the project's branding, functional, production or performance needs.
Distinct Package Design
Create a unique bottle, jar, closure or component with geometry developed specifically for the product or brand.
Functional Requirements
Address dispensing, handling, closure, compatibility or other requirements that existing stock packaging cannot provide.
Packaging Performance
Engineer package geometry, material and component relationships around the needs of the product and production environment.
Cost Optimization
Evaluate whether design, material, tooling or manufacturing changes can support long-term packaging cost objectives.
Sustainability Goals
Consider opportunities such as lightweighting, PCR materials and design changes within the overall package-development process.
Existing Tooling Changes
A custom program may also involve evaluating, modifying, transferring or resourcing an existing mold rather than creating a completely new design.
The Custom Mold Development Process
Empire EMCO's custom mold process follows three connected phases: concept and approval, tooling and production approval, and commercialization.
Concept to Approval
Establish the package requirements and determine whether the proposed concept is technically and commercially viable.
- Project concept
- Engineering review
- Package drawings
- Initial pricing
- Customer review and approval
Tooling & Production Approval
Move the approved concept into detailed tooling development, manufacturing, sampling and production review.
- Final drawings
- Internal approval
- Purchase orders
- Mold manufacturing
- Engineering sample review
- Production approval
Commercialization
Transition the approved package from development into an active commercial packaging program.
- Production release
- Sample and inventory coordination
- Internal release
- Sales and marketing support
- Customer launch
Stock Packaging vs. Custom Packaging
Custom tooling is not automatically the best answer. Empire EMCO can evaluate stock, customized stock, hybrid and fully custom options so the packaging approach fits the project's actual requirements.
| Consideration | Stock Packaging | Custom Packaging |
|---|---|---|
| Initial Tooling | Typically uses existing tooling | May require new or modified tooling |
| Lead Time | Generally shorter | Includes design, tooling and validation stages |
| Design Flexibility | Limited to available package designs | Developed around project requirements |
| Brand Differentiation | Can be enhanced through decoration and components | Can include unique structural design |
| Functional Features | Dependent on available components | Can be engineered into the package |
| Best Fit | Projects where existing packaging meets requirements | Projects requiring unique design, performance or function |
How Much Does a Custom Mold Cost?
There is no single price for a custom packaging mold because the tooling required depends on the package design, manufacturing process and production requirements.
The right question is not simply, "What does a mold cost?" It is, "What tooling solution makes sense for this package, production volume and long-term program?"
Empire EMCO can evaluate the variables that affect tooling and manufacturing costs before a project proceeds to mold production.
How Long Does Custom Mold Development Take?
Custom mold timing varies by design complexity, tooling requirements, manufacturing process, sampling, revisions and approvals. A complete schedule should account for more than mold fabrication alone.
Tooling lead time is only one part of the schedule. Allow time for engineering review, drawings, customer approvals, sample evaluation, revisions when required, production approval and commercialization.
Tool Ownership Should Be Clear Before Production
Tool ownership and usage rights can affect exclusivity, maintenance, future sourcing and what happens if production requirements change.
The appropriate structure depends on the individual project, supplier arrangement and commercial agreement.
Who Owns a Custom Mold?
Custom tooling can be structured in different ways. Ownership, access, exclusivity and usage rights should be understood and documented as part of the mold-development process.
- Customer-owned molds
- Empire-owned molds
- Restricted tooling
- Exclusive tooling
- Shared tooling
- Royalty arrangements
- Licensed tooling
Custom Mold Design Is More Than a Shape
A successful custom package has to move from an idea to a manufacturable component that performs as intended and can be produced consistently.
Empire EMCO's packaging design and engineering resources can support concept development, mechanical design, prototyping, tooling, product evaluation and production implementation.
Custom Packaging Manufacturing Processes
Depending on the package, component and material requirements, custom projects may use different molding technologies.
- Extrusion Blow Molding (EBM)
- Injection Blow Molding (IBM)
- Injection Molding (IM)
- Injection Stretch Blow Molding (ISBM)
Sampling, Validation & Production Approval
A mold is not finished simply because the tool has been built. Samples must be reviewed against the approved package requirements before the program moves into commercial production.
Engineering Samples
Initial samples provide an opportunity to evaluate the molded package and compare it with the intended design.
Review & Validation
Package geometry, components, function and applicable production requirements are reviewed before final approval.
Production Approval
Once the package meets the project's approval requirements, tooling can transition into commercial production.
Continue Exploring Custom Mold Development
Use these resources to evaluate your package concept, engineering requirements and development path.
Packaging Design
Explore package design considerations including shape, material, capacity, neck finish, closure and custom tooling options.
Explore Packaging Design →Innovation & Development
Learn how concept development, prototyping and collaborative packaging innovation can move an idea toward production.
Explore Innovation & Development →Engineering Services
Explore Empire EMCO's conceptual and mechanical design, prototyping, reverse engineering, tooling and evaluation services.
Explore Engineering →Frequently Asked Questions
Common questions manufacturers ask when evaluating custom packaging and mold development.
What is a custom packaging mold?
A custom packaging mold is tooling developed to manufacture a bottle, jar, closure or other packaging component with specific dimensions, geometry, functionality or performance requirements.
When should I consider a custom mold?
A custom mold may make sense when existing stock packaging cannot provide the required shape, functionality, performance, differentiation or other project-specific requirements.
Does custom packaging always require a completely new package?
No. A project may use a fully custom package, modify an existing solution, transfer existing tooling, or combine a stock component with a custom bottle, closure or other component.
What affects the cost of a custom mold?
Tooling cost can be affected by factors including mold construction, number of cavities, package complexity, manufacturing process, automation requirements, neck finish, production volume, surface requirements and validation needs.
How long does custom mold development take?
Timing varies by project. A complete schedule may include concept development, engineering, drawings, approvals, mold manufacturing, sampling, revisions, production approval and commercialization.
Who owns a custom mold?
Ownership depends on the commercial and tooling arrangement. Custom molds may be customer-owned, supplier- or Empire-owned, exclusive, restricted, shared, licensed or subject to other agreed usage terms. Ownership and usage rights should be established for the individual project.
Can an existing mold be moved to another manufacturer?
In some projects, transferring or evaluating an existing mold may be an option. Tool ownership, condition, compatibility, manufacturing capability and contractual requirements should be reviewed before a transfer.
Can I use a stock bottle with a custom closure?
Yes. Hybrid packaging solutions can combine stock and custom components when that approach meets the project's functional, branding and production requirements.
Can sustainability be considered during custom mold development?
Yes. Material selection, lightweighting, PCR options and other sustainability considerations can be evaluated as part of package design and development when appropriate for the project.
What information should I provide to start a custom packaging project?
Helpful information includes what you are packaging, desired size or capacity, material preferences, estimated volume, closure or dispensing requirements, functional requirements, target timing and any existing drawings, samples or tooling.
Explore the Empire EMCO Custom Mold Library
A completely new mold may not be necessary. Empire EMCO maintains an extensive library of existing packaging molds covering bottles, jars, closures, dispensing components and specialty package designs.
Browse existing tooling to identify designs that may provide a starting point for your project or contact our team to evaluate whether an existing or new custom solution makes the most sense.
Have a Custom Packaging Idea?
Start with the package challenge. Tell us what the package needs to accomplish, and Empire EMCO can help evaluate stock, hybrid and custom options before determining the right development path.