BMT, a strategic partner to the global packaging industry, has launched Material DNA: a process development service helps manufacturers define, validate and transfer process windows before production begins.
Material DNA enables manufacturers to move into production while already having the know-how to successfully run the process. By validating process conditions offline and then translating them on the production line using BMT’s preform temperature sensor, THERMOSCAN, the service significantly reduces set‑up time, disruption and financial risk.
“Material DNA gives manufacturers confidence before they commit,” said David McKelvey, Head of Product at BMT. “Instead of learning under pressure on a live production line, teams can define what success looks like in advance and then transfer those validated conditions directly into production.”
Define the process before production begins
Production trials are often constrained by time, material availability and operational priorities, particularly when working with new materials or rPET. With machines running at more than 20,000 bottles per hour, learning through trial and error on the line is costly and sometimes inconclusive.
Material DNA separates material and process learning from these constraints. Using only a small volume of material, typically fewer than 100 preforms, BMT conducts controlled offline experimentation to isolate material behaviour and define a clear, transferable process window. This allows manufacturers to understand operating limits before investing in tooling or production trials.
Bringing validated process knowledge onto the line
Each Material DNA engagement delivers a defined process window and a detailed technical report documenting validated settings, limits and evidence. The service also includes a two‑week THERMOSCAN rental, enabling temperature measurement and real‑time monitoring of process conditions during production line set‑up.
This combination allows teams to transfer validated parameters onto the line with minimal adjustment, reducing commissioning time and increasing the likelihood of right-first‑time production outcomes.
A standardised service for repeatable results
Designed as a standardised, repeatable engagement, Material DNA can be deployed quickly across different machines, sites and products. It provides a consistent, documented approach that helps manufacturers de‑risk major capital investments and accelerate the transition from development to production.
McKelvey continues: “By turning limited material and constrained line access into production‑ready insight, Material DNA supports smarter decision‑making, faster scale‑up and reduced waste, directly supporting BMT’s mission to make sustainability achievable.”
