Case​‍​‌‍​‍‌​‍​‌‍​‍‌ Study: Assisting a UAE Milk Bottles Supplier to Fix Leakage and Cap Fit Problems

The milk bottles supplier who is one of the major contributors in the UAE market came to Minghang after they experienced numerous leakage complaints and noticed that the fitting of the caps is different in the batches that they have tried. Their old molds were not up to the standard of being able to keep close tolerances, which caused dissatisfaction among customers and an increase in the rate of returns. They had to look for a manufacturing partner who can give them the kind of service they need especially in terms of making the sealing of the bottles better.

Locating the Main Problems

Inspection of Molds on the Site

Once the team received the sample milk bottles and caps, the engineering team took measurements of the dimensions and conducted stress tests on them. The results highlighted just these two points as the most important: slightly unevenness along the bottle neck and lack of precision of the cap’s inner thread. In fact, the small deviations were enough to seal breaking during the transport.

Review of Material and Process

Tests were made to check the quality of the raw materials used by the previous supplier and it was found that they mixed the raw materials. By mixing the raw materials, the shrinkage is not uniform during cooling. This disturbs the way the cap fits the thread.

Better Sealing through Custom Redesign

Changing Way Neck and Thread Work

Minghang changed the design of the bottle neck with more tightly controlled dimensions and also refined the thread angle to make sure that the cap fits smoothly, firmly, and tightly. To stop leaking spots a tolerance of 0.05 mm was set.

Quality of Liner Used in Cap and Fitting Upgraded

The threading of the cap was improved and more flexible food-grade liner was used to increase the sealing pressure, thus the re-engineered cap was equipped with these features. To test the compatibility of stacking, vibration, and hot-fill conditions were simulated.

Quality Assurance and Production

Precision in Molding

We introduced a new mold made of hardened steel to keep the long-term stability. The visual inspection during production is automated and it is done for every batch to find the defects of the pieces or the irregularities of the surface.

Leak-Proof Tests and Certification

Pressure, inverted storage, and drop tests were done on randomly chosen samples. The passing percentage went up to 99.2%, which is way higher than what the client had set as a requirement.

Custom 32oz Round Glass Milk Canister with Snap Cap	Custom Vintage Glass Milk Bottles With Lids

Results for the UAE Client

The milk bottles supplier experienced the problem of leakage complaints being reduced to less than 10% after they changed the packaging system. The fit of the cap was so improved that the customer trust level was raised which in turn led to a decline in return rates and stabilization of the long-term supply chain. The client is now collaborating with Minghang for ongoing production as well as for future customization ​‍​‌‍​‍‌​‍​‌‍​‍‌projects. This is some basic, sample markdown.