Case Studies

Automating Your Technology™

Contract Packaging Solution for the Consumer Industry


A startup company came to Keaco for a contract packaging solution for their newly created consumer product. The company needed a plastic lid sealed to the bottom of a small plastic bottle holding their unique ingredients. They wanted the plastic lid sealed hermetically but did not want the plastic lid to be adhesively attached. They were also projecting very high volume production, so the solution not only had to be efficient, it had to provide robust characteristics that would hold up in this demanding environment.


We developed a system where multiple bottles were placed into a custom designed and balanced holding fixture for an ultrasonic welding process. The ultrasonic welding cycle was less than two seconds and 8 bottles would have their lids hermetically sealed simultaneously and then ejected, with 8 more bottles being inserted. The product was then packaged into a display case, boxed, palletized and shipped out for distribution. This new company and product became a great success and millions of bottles are produced annually.

Product Name Contract Packaging
Product Description Ultrasonically welding lids onto plastic bottles then packaging them into boxes, palletizing and shipping to distributor.
Contract Development Capabilities Applied/Processes
  • Ultrasonic Welding
  • Balanced holding Fixture
  • Kitting
  • Boxing
  • Palletizing
Overall Part Dimensions 1″ Diameter lids sealed 8 at a time
Material Used Plastic Bottles, Lids, Display Case
In process testing/inspection performed Visual
Industry for Use Consumer
Delivery Location Packaged in San Antonio, Distributed worldwide
Standards Met Customer Specifications