Bowler Metcalf is a rigid plastic packaging manufacturer, specialising in custom packaging with a high degree of decorating. Its customers include all of the South African national companies as well as a number of international companies such as Johnson & Johnson, Reckitt and Colman, Procter & Gamble, and Lever Brothers to name but a few.

The company was formed in 1972 and listed on the Johannesburg Stock Exchange in 1987 and has a market capitalisation of approximately R110m. It specialises in packaging for the toiletry, cosmetic, pharmaceutical and food market, with high added value and do not actively pursue the large volume, standards market.

Bowler Metcalf has high levels of technical expertise for which it is well renowned. The company has its own mould design department and an extensive toolroom, employing 15 qualified toolmakers. Bowler Metcalf utilise CAD/CAM facilities both in its mould design office and in the toolroom.

The company's modes of manufacture include:

* Extrusion blow moulding - multicavity moulding, up to 5 litres in capacity, in all materials, including PVC, HDPE and P.P.

* Injection blow moulding - Bowler Metcalf is a specialist in roll-on deodorant bottles but is able to produce most products that are suitable for this form of manufacture.

* Injection stretch blow moulding - The PET plant makes a variety of bottles for the carbonated soft drink market up to 2 litres in capacity, as well as wide-mouth bottles up to 2 litres in capacity for the fruit juice market. The company has also developed a library of preforms which enable it to tailor-make specific PET bottles for customers' needs within neck and weight parameters.

* Printing - The company has comprehensive printing facilities which includes screen-printing, both with conventional and UV drying inks, and offset printing, again with both conventional and UV drying inks.

Increase in productivity

The toolroom has increased its productivity by buying a high-speed machine. The company was using Mastercam successfully with their existing conversional NC machines for doing designs, drawings and toolpaths for their blow moulds and plastic injection moulds.

Lance Colborne, a toolmaker, went for a high-speed machining course at the local machine tool supplier. He then realised that he had all the available tools and features needed for HSM on his existing Mastercam software. This was a huge saving for the company due to the high cost of new CAM software. With the help off the local Mastercam dealer, Mecad Systems, the company customised the post processor to suit the high-speed machine.

Today, Bowler Metcalf are achieving highly recognised results on its tools due to the combination of the Mastercam software, the high-speed machine and Lance Colborne's ability to utilise today's technology to is full extent.

Mecad Systems

(012) 665 1400