Background
A well-established brand of extra virgin olive oil in Italy was seeking an effective olive oil bottle factory to upgrade its packaging to improve its exports. The brand needed unique glass bottles of olive oil that would portray the Mediterranean culture but at the same time provide leak-proof functionality during long-haul transportation. They designed bottle was a 500ml dark green Marasca square bottle with a sharp edge, high neck, and a 31.5mm ROPP finish that was compatible with pourers made of aluminum caps. They chose Yeboda due to our accuracy of neck finish adjustment, consistent molde creation and experience in providing food grade glass casing in overseas markets.
Challenges
Oil Seepage Around Cap Area
In overseas transportation, there was a minor leakage of oil on the label and outer cartons because of slight leakages that occurred around the threads of the cap.
Irregular dimensions of neck finish
Minor differences in the ROPP finish diameter resulted in dissimilar crimping resulting in the micro gaps between cap and bottle mouth.
Cause Analysis
Simulations and dimensional tests of sealing have been performed by our engineering team, and the essence of the problems was found to be the following:
- The tolerance of neck finish roundness was excessive and uniform pressure on cap crimping was lowered.
- The sealing surface was slightly distorted by internal stress around the mouth region following annealing.
Solution
Neck Finish Precision Upgrade
We recalibrated neck ring mould and increased our tolerance control as an experienced factory of olive oil bottles. Go/no-go gauges were initiated in the case of each production batch to satisfy dimensional stability.
Better Annealing & Stress Control
We maximized the annealing curve so that there was no residual stress at the mouth of the bottle and the integrity of the shape was retained when capping.
Cap Compatibility Testing
Crimp torque test and tilt leakage simulations were done with the aluminum caps of the client to ensure reliability of their sealing prior to mass production.
Results
The leakage complaints were removed, the performance of cap was stabilized, and the rate of the export damages was reduced significantly. The Italian brand managed to enter into new markets with Europe and Middle East. Through contracting Yeboda to be their long-term olive oil bottle factory, the client acquired the stability of the quality packaging which preserves the value of the product and its brand image.
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