Case Study: Leading Food, Beverage & Packaging Company achieves mirror-surface finishing, reduced press downtime and longer tool life with Proto3000

Cap Compression Molding Tools Polishing For Food, Beverage & Packaging Industries

Leading Food, Beverage & Packaging Company faced inconsistent, time‑consuming manual polishing of compression‑mold punches that caused higher scrap, press downtime and variable appearance. To reach a mirror finish target (Ra 0.05 µm) while preserving tight edge radii, the customer worked with vendor Proto3000 and its DLyte PRO500 solution based on DryLyte Technology.

Proto3000 developed the process (electrolyte, custom fixtures and dry suspension media) and ran 32‑piece batches in ~90 minutes, reducing roughness from ~0.35 µm to below 0.03 µm, keeping internal/external radii under 0.015 mm and removing 0.1 g per piece. The DLyte PRO500 delivered consistent, isotropic finishes, a media lifecycle of ~23,000 parts, throughput of ~160 punches/day (≈40,000/yr), OPEX ≈ €1/part and CAPEX ≈ €4.50/part (5 years), plus >80% production cost reduction, better corrosion resistance and reduced footprint and worker exposure — all achieved by Proto3000.