BMT, a strategic partner to the global packaging industry, has launched Material DNA, a process development service intended to help manufacturers define, validate and transfer process windows before production begins. The solution is intended to enable entry into production with prior knowledge of how to run the process consistently, while reducing start-up time, disruption and financial risk. The service is based on validating process conditions offline and then translating them to industrial conditions using BMT’s preform temperature sensor called Thermoscan.
According to BMT, one of Material DNA’s objectives is to move material and process learning away from the pressure of starting up production on a live line. David McKelvey, Head of Product at BMT, emphasises: "Material DNA gives manufacturers confidence before they commit. 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."
In the background are the typical constraints of production trials such as time, material availability and operational priorities, particularly when working with new materials or rPET. BMT notes that with machines running at more than 20,000 bottles per hour, a trial-and-error approach on the line is costly and the conclusions can be inconclusive. Material DNA is intended to separate these constraints from the phase of understanding material behaviour and process settings.
As part of the offline work, BMT states it conducts controlled experiments using a small volume of material, typically fewer than 100 preforms. The aim is to isolate material behaviour and define a clear, transferable process window. According to the company, this is intended to allow manufacturers to understand operating limits before investing in tooling or undertaking trials on a production line.
Validating and transferring the process window to the line
Each Material DNA engagement is intended to include a defined process window and a detailed technical report documenting validated settings, limits and evidence. The package also includes a two-week Thermoscan rental, which is intended to enable temperature measurement and real-time monitoring of process conditions during production line start-up. The combination of offline validation with on-line temperature control is intended to support the transfer of validated parameters with minimal adjustment, reducing commissioning time and increasing the likelihood of right-first-time output.
Service standardisation and repeatability of results
BMT describes Material DNA as a standardised, repeatable engagement that can be deployed quickly across different machines, sites and products. The company indicates that the documented approach is intended to help reduce risk for major capital investments and accelerate the transition from development to production.
McKelvey adds: "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."
