Background
One of the Spanish dairy brands was in search of a good glass yogurt jar supplier to provide the jars to their new luxury yogurt brand targeting supermarkets and specialty shops. They required glass yogurt containers that were attractive and strong enough to withstand long distance transportation. They tailored jars were 200ml round frosted glass jars with flattened rims, thickened bottoms and smooth shoulder to foil tightly sealed and ornamental lids. They decided on Yeboda due to our experience in designing protective packaging, tightness of molds, and high volume production that is always consistent.
Challenges
Breakage During Transit
The brand suffered a tremendous breakage during shipments through vibration and stacking in pallets and led to delays and incurred unnecessary expenses.
Inconsistent Jar Strength
There was an inconsistency in wall thickness on some production batches and this weakened at the base of the jars or shoulder making them susceptible to cracks upon pressure.
Cause Analysis
Our team found that there were two fundamental problems after inspection and testing:
- Vibration was not completely shielded to the shoulders and rims of the jars by the packaging compartments.
- Capriciousness of the glass forming caused difference in thickness on vital stresses areas, which decreased the resistance to impact.
Solution
Design of Packaging is optimized
Since we are also an advanced glass yogurt jar suppliers, we reinvented carton inserts and cushions that carry the body of the jar and receive shocks when being transported.
Enhanced Glass Distribution
Gob weight adjustment, temperature forming, and annealing curves were used to create a homogeneous wall and base thickness without weak links.
Improvements in Quality Control
New inspection measures also involved drop tests, rim flatness checks and thermal shock checks to make sure jars could survive shipping and handling.
Results
Delivery breakages were reduced by more than 80 percent, consistency in production was enhanced, and Spanish brand has managed to roll out their new line of yogurt throughout the country. The client affirmed this claim by stating that their association with Yeboda as their glass yogurt jar supplier guaranteed them of the protection of their product as well as its appearance to be visually appealing to be displayed in the retail shelf.
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