Context
A customer from the Netherlands reached us with a request to customize Amber 16 oz flip top glass bottles for his premium beer product line. From the beginning, the customer highlighted two important priorities: functionality and brand identity. On the one hand, bottles require bottles required to maintain freshness of beer and carbonation, which offers strong sealing performance. On the other hand, packaging traditionally had to perform amber color associated with craft beer, while the brand was to help stand out in the rapidly competitive European Beer market. The customer was also eager to align the packaging with the premium status of the product, making both practicality and aesthetics necessary.
Challenge
Compared to standard bottles, swing-top bottles involve much more manufacturing complications, especially around the area of the neck where the closure system is fitted. Unlike a simple crown hat, the flip-top closure requires accurate alignment between three components: glass neck, metal swing-top mechanism and sealing gasket. This meant that the design required highly accurate mold engineering to guarantee the correct glass thickness, accurate curvature and tight tolerance of the neck to end. Any small deviation can lead to ceiling failure, leakage risk or incompatible display during bottling. In the worst condition, such issues can reduce the consumer trust and damage the customer’s premium brand image.
Result
Although these challenges were unavoidable, our philosophy was clear: we never compromise on quality nor mislead our customers. To remove technical barriers, we invested additional time and resources in mold refinement, conducted a detailed test, and produced several rounds of prototypes. During the process, we worked in close collaboration with the customer, making sure that their response was integrated into each design recurrence. Finally, we gave a swing-top bottle solution, which not only meets the customer’s technical specifications, but also strengthens their brand vision, supports stability goals, and guarantees reliable performance in alcohol-making and distribution process. The final product was distributed on time, and the customer expressed complete satisfaction with the quality and service provided.
34 oz Glass Swing Top Beer Bottles
Wholesale 16 oz Amber Flip Top Bottles
How We Do It
Preliminary function: Our engineering team conducted a fully feasible study, using advanced modeling to simulate stress points around the area of the neck. The move allowed us to predict potential weaknesses and ensure complete compatibility with the chosen flip-top closure system.
Sample production and adjustment: We prepared an initial set of prototypes and shared them with the customer for evaluation. Based on their response, we laid a target for neck curvature and thickness to customize seal performance and improve handling on automatic filling lines.
Cost customization and mass production: Once the design is valid, we balance the investment carefully against efficient production runs. We adapted packaging to reduce breakdown during transport and kept communication transparent with the customer, providing regular progress updates. This approach ensured timely delivery, controlled costs and a smooth transition in mass production.
EN 
FR 
DE 
IT 
ES 
CS 
PT 
NL 
PL 
TR 
AR 
KO 
JA 
ZH 
RU 
HU