Background
Yeboda was urgently requested for assistance by German a glass oil bottles supplier of glass oil containers. Their specially made oil bottles were resulting in the breaking of half of the pieces while shipping and pallet handling. The problem was customer satisfaction, delivery times, and long-term relationships with European distributors that were endangered.
Understanding the Root Cause
Detailed Structural Analysis
The first phase focused on diagnosing why the custom bottles were failing. After reviewing samples, measurements, and the client’s packaging workflow, our engineering team identified two major issues:
- Uneven glass wall thickness due to mold limitations.
- Insufficient impact resistance around the shoulder and base.
These weaknesses made the bottles vulnerable to vibration and stacking pressure during long-distance transport.
Tailor-Made Manufacturing Improvements
New Mold Optimization
To provide a durable solution, Yeboda redesigned the mold with corrected wall distribution and reinforced stress zones. The improved geometry maintained the client’s aesthetic requirements while significantly strengthening the structure.
Enhanced Annealing and Quality Control
We adjusted the annealing curve to reduce internal stress and added drop-test sampling to ensure consistent durability across batches. Each production stage was monitored to verify stability and repeatability.
Packaging Optimization for Zero-Breakage Delivery
Customized Protective Packaging
In addition to bottle enhancements, we proposed a transport-safe packaging system featuring tighter partition spacing, thicker dividers, and shock-absorbing liners. These updates reduced movement inside cartons and improved pallet stability.
Results and Client Impact
After adopting the revised bottle design and packaging system, the German glass oil bottles supplier saw breakage rates drop from over 7% to below 0.5%. Customer complaints decreased dramatically, and the supplier gained the confidence to promote the new models across more EU markets. This collaboration empowered the client to save costs, protect their brand reputation, and expand their custom product line—all achieved through precise engineering and reliable production support from Yeboda.
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