17# BRING THE PRODUCT TO LIFE

The first manufacturing of the product, in other words bringing the product to life, is an event for the launch of a brand. It is the culmination of the research work and the concretization of the project.

The first product of the brand is the Accord Infini liquid detergent. I am proud to say that it is made in France and that most of its components come from France.

But before the laundry detergent could be bottled, the components of the product had to be manufactured and finalized: the glass bottle, the wooden cap, the double-sided label and the eco-friendly cardboard box.

THE BOTTLE

The making of a glass bottle is an amazing and impressive show.

First, the atmosphere of the glass factory is particular, it is very hot and the place is noisy.

To enter the machine room, it is necessary to wear earplugs, a gown, a cap and protective glasses.

As soon as the production is underway, the magic can happen. The molten glass flows at a temperature of more than 1832 °F (1000°C) and is cut into drops equivalent to the final weight of the bottle.

The drop then falls into the mold which is then blown in two stages:

The first time so that the glass takes the external shape of the bottle.

A second time to shape the inside of the bottle.

The mould is then opened and the still red molten bottle is taken out of the machine with the help of tongs. The bottles then cool down gradually.

Once the production is finished, the bottles are checked by the quality department. They are finally loaded on pallets and ready to be shipped.

THE CARDBOARD BOX

At the same time, the manufacturing of the box was in progress. The case is the component that hides the most complexity in its realization.

It is designed in several stages:

First, after having validated the design of the box, we must validate the printing colors. We call this the Good to Print (GTP). This is the opportunity for me to ensure the intensity of the colors and to make adjustments if necessary.

Cyan, magenta, yellow, black; once these basic colors are validated, I can sign the Good to Print (GTP). Once the GTP is signed, the printing process is launched.

The printed elements are then transferred to be cut and shaped. The box can now take shape.

The assembly of the cabinet is like a ballet of machines.

In the midst of this highly organized ballet, I observe the movements of each machine. In a synchronized movement, they glue the printed paper on what is called the casing of the box, that is to say the rigid form of the box. The two together form the box.

The box is built along the chain. First of all, the lids are covered by the printed paper which takes up the design of the brand.

Then, the inside of the box is integrated by hand with what is called the wedge. This is what will keep the bottle safe in the box. It is in turn covered by the graphics of the product. All these elements are glued manually and meticulously until we obtain the final box that we know today.

Once the box is protected in a plastic bag that will later be recovered and reused, the merchandise is prepared for shipment.

THE CAP

During this time, the manufacture of the wooden cap is taking shape.

To make the shape of the cap, the wood is milled to the shape we know today. As a final touch, the cotton flower is drawn in the center with a laser.
What is impressive is the finesse and speed with which the laser can draw the flower.

Once the cap is shaped, it is placed in a box and prepared for shipment.

THE LABEL

Finally, we finish by the manufacture of the label. The Accord Infini label is quite particular: it is a double-sided label. This technique is called vitrophany.

It is carried out in several stages:

At first, it is the interior part and therefore the drawings that are printed in digital. The digital printing will allow to obtain the least relief possible by depositing very little ink with a very good quality of printing.

Once the printing is finished, it is now the external part and so the text that is done.

The printed reel with the drawings is then transferred to a new machine. A registration is made so that the drawings are perfectly superimposed on the text. Then the production is started, the printing of the text and the relief varnish are added.

The reel will be recovered one last time to cut the paper and give it the rectangular shape of the label.

Once the cutting is finished, the label is ready to be sent.

Each component of the packaging is then sent for the final manufacturing of the product: bottling and boxing.

THE FINAL PRODUCT

This is the final sprint, all components have been delivered.

The lye has been mixed with the perfume concentrate and is ready to be bottled.

On the D-day of production, it’s as if the empty bottles are wriggling impatiently to be transformed into a full finished product.

Waiting on the production line, they are filled in waves of four bottles.

At the end of the line, the bottles are manually closed with the wooden cap and then go automatically to the labeling.

After being labeled, they are checked at the quality control.

Then, they are moved to a table and ready to be placed in the cardboard box.

Once the bottle is added, the box is closed by its lid.
Then, it is secured with a sleeve that is placed around the box to keep it closed and then put under blister to ensure its protection until it arrives at the customer’s.

The product is now ready to be introduced on the market. I now need to take a picture of it and what better way than to call upon a photographer I know.

To be continued…