At Kenray, our Research & Development process turns innovative ideas into robust, production-ready forming solutions. We follow a structured yet flexible approach that balances creativity with rigorous testing to deliver measurable outcomes for our customers and for the business.
Our philosophy is iterative: every prototype and trial feeds back into design. Recent examples include the PTFE Optimised Back Seal (hard back seal with soft-like engagement to mitigate soft-seal detachment risk) and the ongoing Assisted Drop Vertical Forming Set (improving product flow, reducing product-in-seal, and stabilising packs during nitrogen removal).
Clearly define the challenge (e.g., increasing packing speed, improving back seal quality, reducing downtime from component failures).
Generate multiple design concepts using cross-functional expertise in mechanical design, materials science, and packaging engineering.
Rapidly convert concepts into precision-built prototypes for hands-on evaluation.
Run production-relevant trials to measure performance, durability, and efficiency; capture structured test data.
Use data to iterate designs, optimising function, reliability, manufacturability and serviceability.
Validate final designs with extended trials before release to production and customer rollout.
R&D at Kenray is a growth engine. It delivers tangible, trackable value across revenue, margin, risk, and brand.
Suggested KPIs: customer OEE improvement; hours of downtime avoided per line/year; internal scrap/rework rate; service calls per installed base.
Talk to our R&D team today and discover what’s possible for your line.
