Background
One of the dairy brands in the UK wanted to find a good glass yogurt jar factory to create a new top-end line of dessert yogurt to stock the supermarkets. They needed special glass yogurt containers of a unique shape so that they could be visible in chilled shelves. The last design was a tapered round 180ml jar whose rim was slightly flared, the shoulders were smooth, and the base was thickened in order to make it stable. The jar had to hold foil sealing and second plastic lids. After reviewing multiple suppliers, the client selected Yeboda because we offered in-house mold development, strict dimensional tolerance control, and stable high-volume production—key factors for dairy filling lines running at high speed.
Challenges
Inconsistent Mold Replication
Early sampling revealed slight deformation at the rim area. The foil seal did not sit evenly, affecting sealing performance and visual appearance.
Thickness Imbalance at the Base
Some batches showed uneven glass distribution at the bottom, leading to instability on conveyor belts and occasional cracking during rapid cooling after filling.
Cause Analysis
Our engineering team conducted dimensional scans and stress analysis and identified two core problems:
- The initial mold structure lacked optimized venting and alignment, causing minor rim distortion during forming.
- Gob weight distribution was not balanced, creating excessive thickness in some areas and weak points in others.
Solution
Mold Structure Redesign
As an experienced glass yogurt jar factory, we rebuilt the mold with improved alignment precision and optimized venting channels. The rim profile was recalibrated to ensure flatness and consistent sealing surface.
Optimized Glass Distribution
We adjusted gob weight, forming timing, and cooling curves to achieve uniform wall and base thickness. Additional base impact tests were introduced for every production batch.
Enhanced Quality Control
A new inspection protocol was implemented, including rim flatness gauges and thermal shock testing to ensure compatibility with dairy filling processes.
Results
Following these enhancements, the performance became much stronger, and cracking of bases was removed. The efficiency of production was increased and the UK brand managed to introduce its high quality yogurt range across the country. Through their collaboration with Yeboda as their long term glass yogurt jar factory, the client obtained a stable custom mold production and uniform quality packaging that would be ready to be placed in the shops.
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