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Berry Agile Solutions

Design, build and use a testing rig to determine effective insulation for band heaters.

Improving Band Heater Efficiency

Part of the sustainability program, Berry Global expects each of its sites to reduce its energy usage by 1% year on year. As a moulder of plastic parts, Berry Agile Solutions has over 300 moulding machines onsite, each using up to 12 band heaters. Reducing the amount of energy lost in the moulding process by implementing some form of insulation has the potential to substantially improve the efficiency of the moulding process and reduce energy costs.

The aim of this project is to design, build, and use a rig to test insulation methods for band heaters.  You will use of Computer Aided Design (CAD) to design a test rig, which you will then build using a laser cutter, hand tools, electrical wiring, and electrical test equipment. Once your test rig has been assembled, you will develop a process to test the effectiveness of different types of insulation. You will analyse your findings to identify the best method of insulating band heaters and will produce an estimate of the effect of using this insulation across the full plant. You will have the support of three members of Berry Training Academy staff during the project.

You will present your findings in a report detailing how you constructed the testing rig, the results of your testing, and any decisions you made during the project with the reasoning behind them.


Key skills and interests

  • Project management
  • Engineering
  • Data analysis
  • Problem solving
  • Communication
  • Self-motivation
  • Graphic design or computer aided design (CAD)


Host company information

Berry Agile Solutions is a one-stop-shop for companies looking for complete plastic packaging solutions. We mould parts using injection, blow, inject stretch and blow, and extrusion processes to make caps and bottles on to which we can print and perform assembly functions.

Address: London Road, Beccles, Suffolk, NR34 8TS
Key contact: Bob Beard

Visit the Berry Global website for more information about the host company


CREST Awards

This project has been designed to help students achieve a GOLD CREST Award. Download the CREST project guide to help you

File Name File Type File Size File Link
CREST Project Guide PDF 459 KB Download