MACRO optimizes agricultural plastic cabinets with SolidWorks Simulation

This case highlights the success of MACRO, a leading large-scale agricultural cabinet manufacturer, in selecting SolidWorks Simulation Premium software to analyze and optimize the design of its agricultural plastic cabinets.

Company Profile

MacroPlastics, Inc. is recognized as the top manufacturer of large agricultural cabinets in North America. The company has developed a total of 70 different models, which are essential for fruit growers to pick, transport, and sell fruits ranging from apples and oranges to grapes and cherries. These plastic bins are made from high-density polyethylene and polypropylene, offering superior protection compared to traditional wooden crates. They ensure better fruit quality, are washable, reusable, and fully recyclable.

Challenges Faced

As all products are made of plastic, costs have been rising, and the company operates some of the largest high-pressure plastic injection molding machines in the world. Therefore, optimizing material design has become a critical objective. The stackable bins produced by MacroPlastics must withstand heavy loads, and even small savings in material can significantly impact the company's profitability.

“You might think we're just designing a simple product — a plastic box,” explains Todd Turner, senior product development engineer. “But when you consider the size of our products, maintaining strength while reducing weight and determining the complexity of rib structures shows how advanced our product development process truly is.”

Solution

To address these challenges, MacroPlastics chose SolidWorks Simulation Premium software due to its user-friendly interface, seamless integration with SolidWorks CAD software, and comprehensive analysis capabilities. By using SolidWorks design and simulation tools, the company was able to cut development time from months to weeks, tripled the number of new product launches, saved between 30% and 60% in capital costs, and reduced overall product weight by 10% to 25%.

“Without finite element analysis (FEA), we couldn’t have achieved this level of product development,” Turner said. “Since the first version of SolidWorks design software came out, I’ve been using it. Choosing an FEA tool that integrates well with the platform was a natural decision. SolidWorks Simulation is very easy to use and fits perfectly into our workflow.”

“With SolidWorks Simulation, I can identify and resolve potential issues during the design phase, ensuring that when we produce the original parts, they work on the first try. It’s an incredible tool that has helped us save 30% to 60% in capital costs for new product development.”