Example-Project: Adblue Tank

Requirements of the customer

  • Quantity: 80.000 – 150.000 pcs. (large series)
  • Development time: 3 – 4 months
  • Target: The target was to develop an Adblue tank quickly and with low tool costs. The tank should have several openings for sensors and the add-on parts (control unit, pump, filter, relay) should be able to be attached directly to the tank.
  • Individual serial number assignment with complete batch traceability


  • Short development time and budget
  • Guaranteed tightness when screwing the sensors
  • Deformation resistance of the tank in frost
  • Secure attachment of the attachments to the tank to dampen vibrations
  • Chemical resistance of all components against urea

COOP’s Approach

  • Weighing up the feasibility with the individual manufacturing processes for plastic parts (blow moulding, rotational moulding, deep drawing, injection moulding). The selection was based on a number of factors, including technical feasibility, tool costs incurred, the cost and duration of tool making, the cost of parts for series production, the risk of change and scalability.
  • Selection of the manufacturing process and final design in CAD
  • Tool making and sampling within 3 weeks
  • Tool making for moulded hoses within 10 days
  • Construction of production line incl. mirror welding and pressure testing
  • Development of packaging concept for safe transport

Use our all-round service

  • Personal customer advice and support
  • New development, further development, cost optimization
  • Creation of concept drawings, production drawings and material lists (BOM)
  • Fast prototyping
  • Creation of initial sample inspection reports (ISR)
  • Demand-oriented production
  • International serial supply
  • Computer-aided process documentation
  • Batch Traceability
  • Continuous quality monitoring

Any more questions?

We are happy to advise you and provide you with a non-binding offer.

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