PRODUCT LIFE CYCLE

As specialists in plastic beverage crates, we support your project from the development of ideas to series production. Product development is our absolute strength, thanks to our many years of experience, a consistently creative approach, and a high degree of vertical integration. The production of beverage crates in all designs is our absolute core competence. Learn more about product development here.

1. Design, development, and conception

For us, the development of a beverage crate always begins with the customer: in a personal meeting, we work together to analyze the requirements in terms of functionality, design, stability, and brand impact. Whether it's a classic beer crate, a modern water crate, or an innovative packaging concept for soft drinks—our goal is to create a solution that is both technically and visually impressive.

The next step is the design phase, which is carried out by our experienced development team. Based on the customer's specifications, initial 3D design drafts and construction models are created, which are optimized in terms of ergonomics, stackability, weight, and logistics processes. We pay particular attention to the integration of branding elements such as embossing, color design, or in-mold labeling in order to effectively convey the customer's brand identity.

2. Prototype construction

As part of the sample construction process, we manufacture functional prototypes of beverage crates, which serve as the first tangible implementation of a new product idea. These samples are not produced using injection molding, but rather from wood, plastics, and existing components—quickly, flexibly, and with a perfect fit.

The aim is to provide the customer with a clear model at an early stage that simulates both the design and key functional features such as shape, size, comfort, and layout. These prototypes enable a practical assessment of ergonomics, handling, and aesthetics—even before investing in costly tool manufacturing.

By combining different materials, we can accurately represent design details and make quick adjustments as needed. Prototype construction thus forms an important bridge between design and series development and creates the basis for informed decisions in the further development process.

3. Series production

Once the prototype and tooling have been approved, Delbrouck begins structured series production of beverage crates. The basis for a smooth start to production is the entry of all relevant master data into the ERP system, including parts lists, work plans, quality specifications, and logistics parameters. At the same time, all necessary components are procured—from color granules and labels, for example for in-mold labeling, to pallets and packaging materials.

Our production planning ensures that all materials and tools are available on time. Experienced specialists then set up the injection molding machines and peripheral equipment according to specified process parameters. For each product variant, machines, tools, and automation components are optimally coordinated to ensure an efficient and stable production process. Depending on the geometry and features of the respective product, the cycle time is around 55 seconds per shot.

4. Quality assurance

The defined product quality is ensured by clear test characteristics, start-up approvals, and first article approvals. During ongoing operations, continuous quality control is performed by means of visual inspection, dimensional control, and, if necessary, automated testing systems. Deviations are immediately documented and analyzed to ensure maximum process stability.

After approval by internal quality assurance, the finished boxes go directly to the shipping area. There, they are palletized, packaged, and prepared for shipment according to customer requirements. Our structured production and logistics chain ensures that every delivery is made just-in-time or according to defined call-off schedules—ready for delivery, on time, and in consistently high quality.

5. Warehousing and logistics

In the area of warehousing and logistics, we ensure that production is supplied with raw materials and pallets seven days a week at two locations.
The finished products are stored outdoors and delivered according to customer specifications
. We organize most of the product deliveries ourselves. We work with around 20 companies that use jumbo articulated trucks.
During peak periods, we also use an online freight exchange.
In 2024, we delivered a total of 1,850 full loads to customers from both locations.

DELBROUCK has a total of more than 40,000 square meters of open storage space for storing bottle crates. From these warehouses, the products are fed into the ongoing filling processes just in time by freight forwarders, in close consultation with the customer's logistics provider.

6. Tool maintenance

Our tool maintenance department ensures that injection molds are ready for use at all times. Using state-of-the-art technology such as milling centers and erosion machines, we reliably maintain and repair tools and manufacture replacement parts as needed in the shortest possible time. This allows us to keep downtime to a minimum and ensure smooth operations.

The 13-strong team—affectionately known internally as "The Wild 13"—stands for flexibility, adherence to deadlines, and innovation. One of its particular strengths lies in gas-assisted injection molding, which saves material, shortens cooling times, and ensures stable, low-warpage surfaces. Thanks to our 24/7 on-call service, we are always there for our customers.