Water Tanks & Rotomoulding · Leading Australian rotomoulding powder + tank component manufacturer
Cutting a key component's cost by designing out its secondary processes — and unlocking a sales rebound
Before
A leading Australian manufacturer of rotomoulding powders and water tank components was watching one of their key parts price itself out of the market. The component itself was sound, but labour-intensive secondary processes meant every unit carried hidden cost. Sales softened. They needed the secondary work designed out, not optimised.
What we built
We worked through the part with the client's team to understand exactly which features were design and which were retrofit. Then we designed and manufactured three injection moulding tools covering the full size range, with the secondary operations consolidated into the moulding step. Production simplified to a single workflow.
The result
Per-unit cost dropped, sales recovered, and the client moved into adjacent market segments using the margin headroom — exactly the outcome they'd been chasing.
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