Background
A fast-growing Brazil hot sauce bottles manufacturer came to Yeboda with the need to help them fix serious problems with cap leakage which had negative impacts on product presentation, the increase in returns, and, consequently, the decrease of their market expansion. So, as a startup with a desire to scale up very fast, they were in dire need of a sealing solution that was both reliable and customized to their situation.
Challenges
Leakage Under Heat and Pressure
It is known that the hot sauce has vinegar, oil, and spices, as components, and for that reason, the bottles emitted liquid when transport and temperature changes caused them to shake. The existing caps were not able to provide a tight seal, thus the sauce found its way out and additionally, it stained the packing.
Incompatible Cap and Bottle Fit
The suppliers of the bottle neck and the cap were different; therefore, the threads had different angles. Some of the caps could not fit properly, while others were only halfway sealed, thus leaking was increasingly likely during the process of transportation.
Yeboda Solutions
Precision-Engineered Bottle Neck
By Yeboda redesigning the bottle neck, the tolerance range became stricter and the thread pitch was more consistent. Every cap, as a result, was able to fit securely and evenly, thus ensuring that micro-gaps that caused leakages were eliminated.
Upgraded Food-Grade Liner Insert
We suggested that they use liners that can resist pressure and at the same time, be compatible with acidic and oily condiments. These liners not only ensured the sealing of the hot sauce bottles, but also gave the bottles the ability to be squeezed, transported for long distances, and be stored in hot places without losing their sealing capability.
Real-World Leakage Simulation Tests
To support the changes made, Yeboda carried out thermal cycling, drop, and inverted storage tests. In the redesigned bottles, the leak-proof seal was there even after these tests.
Results
The Brazil hot sauce bottles manufacturer managed to lower the amount of leakage by a huge margin to a level that was less than 10% of what had been reported just a few weeks ago within a very short period of time. It is a result of this that their products were not only reaching customers in a hygienic condition and visually becoming more appealing on shelves, but the taste and the freshness of their products were also being kept. This consistency provided the confidence the startup needed to extend their distribution to supermarkets and larger retailers.
Conclusion
With the help of Yeboda and through the processes of perfecting packaging designs, improving the quality of materials used in sealing, and putting the products through vigorous tests, the manufacturer got rid of the leakage problems as well as gained the trust of their brand. Thanks to the upgraded packaging, they were able to grow their business without worries and in line with the standards of the industry.
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