Background
Our client, Juice do Brasil, is a leading spice jar dealer that supplies premium organic seasonings to high-end supermarkets across South America. They approached Yeboda to customize a signature line of glass spice jars: a square 4oz flint glass bottle equipped with a dual-function flip-top shaker lid and a custom brushed aluminum finish. They chose Yeboda because of our integrated production capabilities and our ability to provide a “one-stop” solution—from custom glass molding to specialized cap engineering—that other manufacturers couldn’t match.
Challenges
Before partnering with Yeboda, the spice jar dealer faced two critical market complaints that threatened their contracts with major retailers:
- Impact Fragility: The previous jars suffered from high breakage rates during the automated filling process and local transit, specifically at the “shoulder” of the square bottle.
- Aroma Leakage: The spices (particularly fine-ground peppers and powders) were losing their potency within three months, suggesting a failure in the airtight integrity of the shaker lids.
Cause Analysis
Upon receiving samples of the failed units, the Yeboda engineering team performed a Polarized Light Stress Analysis and a Vacuum Leakage Test. We identified two core issues:
- Uneven Glass Distribution: The square mold design caused the glass to be too thin at the corners and shoulders, making them susceptible to “thermal shock” and physical impact.
- Liner Incompatibility: The standard pressure-sensitive liners were reacting with the essential oils found in the Brazilian spices, causing the adhesive to degrade and breaking the airtight seal.
Solution
- Redesigned Mold Geometry: We adjusted the parison (molten glass pre-form) distribution to thicken the walls at the corners by 15%, significantly increasing the “Vertical Load Strength.”
- Induction Heat Sealing (IHS): We changed the client to high-performance liners to Induction Heat Seal liners. This forms a seal that is hermetic and tamper-evident, which is impervious to the oils of spice and ensures 100% aroma preservation.
Results
Yeboda was able to change the product line of the client with the intervention:
- 98 percent Breakage Reduction: The reinforced glass building practically destroyed the losses in the high-speed filling process.
- Long Shelf Life: Lab tests established that the spices can maintain 95 percent of their aromatic strength to as long as 18 months.
- Market Dominance: Juice do Brasil has been able to acquire three new nationwide retail accounts in six months using a superior product.
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