Background
One of the leading brands of Japanese pickles was seeking a stable pickle jar wholesaler to provide a new line of retail stores and exporting outlets. They required bespoke glass pickles jars with an unobtrusive, sleek appearance: 350ml round-shouldered jar, high clarity flint glass, a slim neck with smooth edges, and a large lug cap to fill easily with sliced cucumbers and mixed vegetables. They chose Yeboda due to their ability to offer in-house development of molds and consistent mass production and better dimensional control, which is important to Japanese packaging demands and automated capping lines.
Challenges
Mold Sampling Delays
The custom mold of their former supplier continued to fail during trial runs resulting in inconsistent jar thickness and frequent delays in sampling.
Cap Fit & Vacuum Issues
The performance of the lug cap was mixed even in cases where jars were appealing. Other jars were found to lose their vacuum following pasteurization and hence leakage complaints.
Cause Analysis
The drawings, samples, and production data were checked by our engineers and proved the root causes:
- The neck (finishing) size was not constant because of inappropriate alignment of the molds and scratched neck rings.
- The jar body was not evenly distributed with glass material and formed weak points which influenced the vacuum stability after heat processing.
Solution
Redesigning Molds and + Precision Control
We refiruged the mold structure to use better alignment points and better neck ring materials to maintain the 82mm lug finish.
Process Optimization for Glass Jars
In order to enhance durability and sealing, we made changes to forming parameters and enhanced inspection:
- Maximized gob weight and temperature ratio to minimize variation in thickness.
- Introduced batching checks on added finish gauges.
- Tested the glass jars to an introduced thermal shock and vacuum retention tests.
Results
Leakage failures dropped by over 85%, torque stability improved significantly, and the Poland brand successfully launched both sparkling and still water lines. The project confirmed Yeboda as a dependable long-term glass water bottle factory partner for high-performance beverage packaging.
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