{"id":654,"date":"2026-04-24T08:22:25","date_gmt":"2026-04-24T08:22:25","guid":{"rendered":"https:\/\/isbm-blow-molding.com\/?p=654"},"modified":"2026-04-24T08:22:25","modified_gmt":"2026-04-24T08:22:25","slug":"isbm-cavity-count-calculator-how-many-cavities-do-you-actually-need","status":"publish","type":"post","link":"https:\/\/isbm-blow-molding.com\/fr\/isbm-cavity-count-calculator-how-many-cavities-do-you-actually-need\/","title":{"rendered":"Calculateur de nombre de caries ISBM\u00a0: De combien de caries avez-vous r\u00e9ellement besoin\u00a0?"},"content":{"rendered":"
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DECISION TOOL<\/p>\n

Calculateur de nombre de caries ISBM\u00a0: De combien de caries avez-vous r\u00e9ellement besoin\u00a0?<\/h1>\n

Choosing 4 cavities when you need 8 caps your production at half capacity. Choosing 16 when you need 8 doubles your mould investment and adds changeover friction. This guide provides the formula, scenario calculations, and hidden cost framework to land on the right cavity count for your Korean production line.<\/p>\n

Request Cavity Count Assessment \u2192<\/a><\/p>\n<\/div>\n<\/section>\n

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TL;DR \u2014 R\u00e9sum\u00e9 rapide<\/p>\n

Calculate cavity count using: Annual bottles = Cavities \u00d7 (3600 \/ cycle time) \u00d7 operating hours \u00d7 uptime factor<\/strong>. For 5-50ml pharma vials target 12-16 cavities; 50-300ml cosmetic 6-12 cavities; 300-800ml beverage 4-8 cavities; 1-2L wide-mouth 2-4 cavities; 5L large format 1-2 cavities. Higher cavity counts reduce per-bottle cost but increase mould capital 30-50% and changeover time 40-60%. For multi-SKU portfolios, select cavity count matching your highest-volume SKU and accept lower efficiency on smaller runs rather than undersizing for the largest.<\/p>\n<\/div>\n

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Dans ce guide<\/h3>\n
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  1. Why Cavity Count is the Hardest Decision<\/a><\/li>\n
  2. The Core Capacity Formula<\/a><\/li>\n
  3. Three Real Scenario Calculations<\/a><\/li>\n
  4. Cavity Count by Bottle Volume<\/a><\/li>\n
  5. Ever-Power Platform Matching<\/a><\/li>\n
  6. Hidden Costs of Higher Cavity Count<\/a><\/li>\n
  7. Multi-SKU Flexibility Strategy<\/a><\/li>\n
  8. Korean Scaling Patterns: 1 to 10 Machines<\/a><\/li>\n
  9. Foire aux questions<\/a><\/li>\n
  10. Conclusion<\/a><\/li>\n<\/ol>\n<\/div>\n

    <\/p>\n

    1. Why Cavity Count is the Hardest Decision<\/h2>\n

    After you choose the machine platform and bottle design, cavity count becomes the final critical decision before purchase order. Unlike most ISBM procurement decisions where buyers default to vendor recommendations, cavity count requires the producer’s own input because it depends on production volume assumptions only the buyer can forecast accurately.<\/p>\n

    \u00a0 \"application<\/p>\n

    The asymmetric risk makes this decision uncomfortable. Undersized cavity count caps production capacity permanently and cannot be retrofitted without buying a second machine or new mould. Oversized cavity count inflates mould capital cost 30-50% and introduces changeover friction that hurts multi-SKU production efficiency. Neither error corrects cheaply.<\/p>\n

    Korean producers typically arrive at the cavity count conversation after six weeks of bottle design work and machine evaluation. At that point, the forecasting discipline has often lapsed because everyone assumes the numbers are already locked in. This is exactly when the most expensive selection errors happen. The framework below converts cavity count from intuition into measured calculation.<\/p>\n

    <\/p>\n

    2. The Core Capacity Formula<\/h2>\n

    Annual cavity count calculation uses four inputs: cavity number, cycle time, operating hours, and uptime factor. The output is annual bottle capacity. Work backward from your target annual volume to determine required cavity count.<\/p>\n

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    CORE FORMULA<\/p>\n

    Annual Bottles = Cavities \u00d7 (3,600 \u00f7 Cycle Time) \u00d7 Operating Hours \u00d7 Uptime Factor<\/p>\n

    Cycle time in seconds. Operating hours per year. Uptime factor 0.90-0.98.<\/p>\n<\/div>\n

    Input Reference Values<\/h3>\n
    \n\n\n\n\n\n\n\n\n\n\n\n\n
    Input Parameter<\/th>\nGamme cor\u00e9enne typique<\/th>\nNotes<\/th>\n<\/tr>\n<\/thead>\n
    Cycle time (50-300ml bottle)<\/td>\n9-12 seconds<\/td>\nDepends on wall thickness + resin<\/td>\n<\/tr>\n
    Cycle time (500-1000ml)<\/td>\n11-14 seconds<\/td>\nLonger cooling for larger bottle<\/td>\n<\/tr>\n
    Cycle time (1-2L)<\/td>\n14-18 seconds<\/td>\nHeavy wall + thermal mass<\/td>\n<\/tr>\n
    Cycle time (5L gallon)<\/td>\n25-35 seconds<\/td>\nLarge thermal mass, heavy clamping<\/td>\n<\/tr>\n
    Single shift (8 hr)<\/td>\n2,000 hours\/year<\/td>\n250 days \u00d7 8 hours<\/td>\n<\/tr>\n
    Two-shift (16 hr)<\/td>\n4,000 hours\/year<\/td>\n250 days \u00d7 16 hours<\/td>\n<\/tr>\n
    Three-shift \/ 24-7<\/td>\n6,000-7,500 hours\/year<\/td>\nDepends on holiday \/ maintenance calendar<\/td>\n<\/tr>\n
    Uptime factor (Korean tier)<\/td>\n0.95-0.98<\/td>\nIncludes changeover, maintenance, small stops<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

    Use conservative uptime assumptions for first-year calculations. Korean producers running mature production lines on full-servo platforms commonly achieve 0.97-0.98 uptime. New installations during commissioning typically run 0.90-0.93 until operator experience and parameter optimization stabilize. Understate rather than overstate capacity during procurement calculation.<\/p>\n


    \n<\/p>\n

    3. Three Real Scenario Calculations<\/h2>\n

    The following three scenarios demonstrate the cavity count calculation for common Korean production profiles. Each scenario applies the same core formula to show how inputs drive the cavity decision.<\/p>\n

    Scenario A: 1 Million Bottles per Year, Single Shift<\/h3>\n
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    EMERGING K-BEAUTY BRAND<\/p>\n

    Entr\u00e9es :<\/strong> 100ml PETG cosmetic bottle, 11-second cycle, single 8-hour shift, 0.95 uptime factor, 1M annual bottle target<\/p>\n

    Calcul:<\/strong> 1,000,000 = Cavities \u00d7 (3,600 \u00f7 11) \u00d7 2,000 \u00d7 0.95<\/p>\n

    Solving:<\/strong> Cavities = 1,000,000 \u00f7 (327 \u00d7 2,000 \u00d7 0.95) = 1.6<\/p>\n

    Recommendation:<\/strong> 2-cavity mould on compact 4-station platform. Provides 25% capacity headroom for demand growth. HGY50-V3-EV precision platform<\/a> ou HGY150-V4 4-station<\/a> matches this scale.<\/p>\n<\/div>\n

    Scenario B: 5 Million Bottles per Year, Two Shifts<\/h3>\n
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    MID-SIZE CONTRACT FILLER<\/p>\n

    Entr\u00e9es :<\/strong> 250ml PET cosmetic bottle, 10-second cycle, two-shift operation (4,000 hours\/year), 0.96 uptime factor, 5M annual target<\/p>\n

    Calcul:<\/strong> 5,000,000 = Cavities \u00d7 (3,600 \u00f7 10) \u00d7 4,000 \u00d7 0.96<\/p>\n

    Solving:<\/strong> Cavities = 5,000,000 \u00f7 (360 \u00d7 4,000 \u00d7 0.96) = 3.6<\/p>\n

    Recommendation:<\/strong> 4-cavity mould provides matched capacity with marginal headroom. 6-cavity provides 40% headroom for growth and downtime absorption. For AOKI 250 mould compatibility preservation, choose HGY200-V4-B platform<\/a>.<\/p>\n<\/div>\n

    Scenario C: 20 Million Bottles per Year, Three Shifts<\/h3>\n
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    LARGE BEVERAGE PRODUCER<\/p>\n

    Entr\u00e9es :<\/strong> 500ml PET water bottle, 9.5-second cycle, 24-hour three-shift operation (7,000 hours\/year), 0.97 uptime factor, 20M annual target<\/p>\n

    Calcul:<\/strong> 20,000,000 = Cavities \u00d7 (3,600 \u00f7 9.5) \u00d7 7,000 \u00d7 0.97<\/p>\n

    Solving:<\/strong> Cavities = 20,000,000 \u00f7 (379 \u00d7 7,000 \u00d7 0.97) = 7.8<\/p>\n

    Recommendation:<\/strong> 8-cavity mould on Quai \u00e0 4 stations HGY200-V4<\/a>. For buffer capacity and double-row efficiency, consider HGY250-V4-B double-row<\/a> for higher throughput in similar footprint.<\/p>\n<\/div>\n

    <\/p>\n

    4. Cavity Count by Bottle Volume<\/h2>\n

    Bottle volume imposes physical constraints on maximum cavity count. Clamping force, injection capacity, and mould footprint all limit how many cavities fit on a given machine platform. The following table shows typical cavity count ranges by bottle volume family.<\/p>\n

    \n\n\n\n\n\n\n\n\n\n\n\n\n\n
    Volume de la bouteille<\/th>\nTypical Cavity Range<\/th>\nApplication<\/th>\n<\/tr>\n<\/thead>\n
    5-50 ml<\/td>\n12-16 cavity<\/td>\nPharma vials, serum bottles<\/td>\n<\/tr>\n
    50-150 ml<\/td>\n8-12 cavity<\/td>\nSmall cosmetic, pharma<\/td>\n<\/tr>\n
    150-300 ml<\/td>\n6-12 cavity<\/td>\nK-beauty standard, pharma syrup<\/td>\n<\/tr>\n
    300-500 ml<\/td>\n4-8 cavity<\/td>\nBeverage commodity, body lotion<\/td>\n<\/tr>\n
    500-1,000 ml<\/td>\n4-8 cavity<\/td>\nBeverage, household chemical<\/td>\n<\/tr>\n
    1-1.5 L<\/td>\n2 \u00e0 6 cavit\u00e9s<\/td>\nLarge beverage, wide-mouth jars<\/td>\n<\/tr>\n
    1.5-2 L<\/td>\n2-4 cavity<\/td>\nLarge beverage, food jars<\/td>\n<\/tr>\n
    2-4 L<\/td>\n1-2 cavity<\/td>\nBulk food, large container<\/td>\n<\/tr>\n
    5-6 L<\/td>\n1-2 cavity<\/td>\n5L water gallon, B2B hospitality<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

    These ranges reflect practical production configurations. Theoretical maximum cavity counts can exceed the ranges shown, but practical cavity count is constrained by three factors: preform weight affecting injection clamping force requirements, bottle body dimensions affecting blow mould footprint, and cooling capacity affecting cycle time consistency across all cavities.<\/p>\n


    \n<\/p>\n

    5. Ever-Power Platform Matching<\/h2>\n

    Platform selection and cavity count must match. The following matrix identifies the maximum cavity count supported by each Ever-Power platform and the typical sweet spot for production efficiency.<\/p>\n

    \n\n\n\n\n\n\n\n\n\n\n\n\n\n
    Platform<\/th>\nMax Cavities<\/th>\nVolume de la bouteille<\/th>\n<\/tr>\n<\/thead>\n
    HGY50-V3-EV<\/a><\/td>\nUp to 16<\/td>\n5-50ml pharma vials<\/td>\n<\/tr>\n
    HGY150-V4<\/a><\/td>\nUp to 12<\/td>\n50-300ml cosmetic, pharma<\/td>\n<\/tr>\n
    HGY150-V4-EV<\/a><\/td>\nUp to 12<\/td>\nPremium PETG, K-beauty<\/td>\n<\/tr>\n
    HGY200-V4<\/a><\/td>\nUp to 8<\/td>\n300-800ml beverage<\/td>\n<\/tr>\n
    HGY200-V4-B<\/a><\/td>\nUp to 8<\/td>\nAOKI 250 format, 250ml<\/td>\n<\/tr>\n
    HGY250-V4<\/a><\/td>\nUp to 6<\/td>\n500ml-1.5L wide-mouth<\/td>\n<\/tr>\n
    HGY250-V4-B<\/a><\/td>\nUp to 12 (double-row)<\/td>\nHigh-throughput 1-2L<\/td>\n<\/tr>\n
    HGY650-V4<\/a><\/td>\nUp to 2<\/td>\n5L water gallon, large format<\/td>\n<\/tr>\n
    EP-HGYS280-V6<\/a><\/td>\nUp to 8 (6-station)<\/td>\nComplex asymmetric premium<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

    The double-row HGY250-V4-B deserves special note. Its architecture delivers up to 12 cavities in similar footprint to standard 6-cavity single-row platforms, effectively doubling throughput density for 1-2L bottle applications without requiring additional floor space or a second machine.<\/p>\n

    <\/p>\n

    6. Hidden Costs of Higher Cavity Count<\/h2>\n

    Higher cavity count reduces per-bottle production cost through economies of scale, but introduces hidden costs that are often underestimated during procurement. Korean producers should factor these costs into cavity decision.<\/p>\n

    \"Moule<\/p>\n

    Mould Capital Cost Scaling<\/h3>\n

    Mould capital cost does not scale linearly with cavity count. Each additional cavity adds roughly 40-60% of the single-cavity cost due to shared infrastructure (base plates, hot runner manifold, cooling circuits). Typical Korean market pricing for 250ml cosmetic bottle moulds:<\/p>\n