During manufacturing of hot cast product 20% of the mixture curing in the packaging generated volume shrinkage, dents and deformations which rendered the product unavailable for sale, thus being subject to removal.


The production process as well as raw materials, equipment and technologies being used were all analysed. The source of this problem was determined, being too high temperature difference between the mixture being cast and the storage packaging. By raising the packaging temperature to a room temperature, the off spec product ratio dropped to 4%. Due to eliminate such problem, a remedy system was developed allowing to get rid of this issue.


  • The off spec product ratio, being a waste product, was reduced to zero
  • The company generated savings (waste reduction, no utilisation costs) and increased production efficiency (no need to make larger product batches);