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Redesigned capsules drive profits for Belron

Belron,the world’s largest vehicle glass repair and replacement company that owns AUTOGLASS®, CARGLASS® and ELITE AUTO GLASS®, came to PDD when it wanted to expand its windscreen repair service using a new resin technology housed in capsules.

The new capsules needed to withstand the rigours of storage and transport across the globe and needed to be easy to manufacture in large quantities. To understand how we could improve the quality and increase the efficiency of manufacturing the capsules, we analysed the existing capsules using extreme environmental tests to replicate storage and transport conditions.

After identifying areas for improvement, we re-designed the capsules to be insensitive to climatic variation using new sealing and assembly methods. We specified a robust manufacturing process, built a pilot plant to optimise the process parameters for quality, and managed the tooling, moulding and capsule approvals with a newly-sourced manufacturer. To increase production, we managed the development of semi-automated assembly and filling plant and provided ongoing technical and quality-assurance management.

The new capsules and production line reduced the failure rate by 20 percent and led to a 5-fold production increase, helping Belron® achieve its business objectives. The capsule design was shortlisted for a European Strategic Manufacturing Award.


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BelronIt’s very rare to find a partner that offers the full service. PDD does just that. It identified a number of innovative opportunities, from natural technical evolution to truly blue-sky ideas that will revolutionise future business. PDD is our first port of call for any problem.

Chris Davies, Belron® Technical