INSTAPLAST Pvt. Ltd
Production of Plastic Preforms for Beverage Industry
Solutions Implemented
The Challenge
Defects were slipping through quality control—customers were complaining about inconsistent product
Production batches couldn't be tracked—no way to identify which batch had problems or trace them back
Scheduling was done manually on paper—constant production line delays and bottlenecks
Nobody knew where costs were actually going—material wastage was bleeding them dry
How We Did It
Built a quality management system that catches problems before products leave the facility
Implemented batch tracking so every preform is tagged and traceable from raw material to shipment
Automated production scheduling based on actual demand—no more guessing or paper schedules
Set up detailed cost tracking and waste reporting to identify where money was being wasted
The Results
Quality Defects
45% reduction
Production Schedule Accuracy
92%
Material Wastage
28% decrease
What They Gained
Customers now get consistent, reliable quality—fewer complaints and returns
Full traceability means if a problem appears in the field, they can identify exactly which batch it came from
Production runs smoothly without constant stop-and-start due to poor scheduling
Cost per unit is much clearer—they can see exactly where the money is going
Orders get fulfilled on time, which means their biggest beverage industry customers are much happier
By the Numbers
Daily Production Capacity
100+ tons
Customers Served
20+
Quality Improvement
45%
Ready for Your Own Success Story?
INSTAPLAST Pvt. Ltd transformed their operations. So can you. Let's talk about what's possible for your business.