Research & Development
The Kenray R&D Process
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 Process
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).
Problem Identification
Clearly define the challenge (e.g., increasing packing speed, improving back seal quality, reducing downtime from component failures).
Concept Development
Generate multiple design concepts using cross-functional expertise in mechanical design, materials science, and packaging engineering.
Prototyping
Rapidly convert concepts into precision-built prototypes for hands-on evaluation.
Testing & Data Collection
Run production-relevant trials to measure performance, durability, and efficiency; capture structured test data.
Refinement
Use data to iterate designs, optimising function, reliability, manufacturability and serviceability.
Validation & Handover
Validate final designs with extended trials before release to production and customer rollout.
Business Value
R&D at Kenray is a growth engine. It delivers tangible, trackable value across revenue, margin, risk, and brand.
Revenue Growth & Differentiation
• Win new business with demonstrably faster machines and higher seal quality.
• Premium pricing for IP-backed forming sets (e.g., PTFE Optimised Back Seal) that solve chronic industry issues.
• Market expansion into produce/salad verticals via Assisted Drop solutions.
Margin & Cost Efficiency
• Reduced downtime: hard back seal design avoids soft-seal migration into product stream and prevents undetected contamination, converting failures into predictable jaw jams that are quicker to resolve.
• Lower service burden through more durable components and standardised designs.
• Manufacturability: designs optimised for repeatability reduce scrap and rework.
Suggested KPIs: customer OEE improvement; hours of downtime avoided per line/year; internal scrap/rework rate; service calls per installed base.
Quality, Compliance & Risk Reduction
• Consistent seal integrity across uneven heater bars through maximised contact geometry. • Food safety: minimises risk of foreign body contamination from soft seals and improves detectability. • Regulatory confidence for customers in high-compliance sectors.
Intellectual Property & Defensible Advantage
• Patentable innovations (e.g., PTFE Optimised Back Seal) create barriers to entry and strengthen negotiations.
• Brand authority through documented R&D rigour and published case results.
Customer Retention & Lifetime Value
• Measurable outcomes (higher speeds, fewer end-seal rejects) build trust and lock-in. • Data-driven service: trial data and validation reports become assets for customer QA and continuous improvement.
How We Work With Customers
Co-definition of success criteria (speeds, reject rates, changeover times).
Transparent trials with structured data and before/after comparisons.
Handover packs: validation report, settings, maintenance guidance, and operator training notes.
Ready to solve your packaging challenges?
Talk to our R&D team today and discover what’s possible for your line.
