Case Study: How a Glass Water Bottle Supplier Solved Leakage Issues for Brazil Brands

Client Background

One of the Brazilian premium water brands was in need of a good glass water bottle supplier to help launch new sparkling and still water products. They needed glass water bottles which were not only beautiful but also had long distance distribution ability in terms of airtight seals. The brand filled 500ml clear cylindrical bottles with reinforced base, smooth straight walls and 28mm PCO neck finish that allows tamper evidence caps. They selected Yeboda due to our existing track record of producing quality glass bottles that are leak proof and our skills of controlling the whole process 360 that includes the moulding process to the packaging process.

Challenge

Leakage in the course of filling the carbonated water.

The first test runs revealed the presence of micro-leakage following carbonation and disrupted the product shelf-life and posed risk to export- shipments.

Unreliable Sealing Torque.

Cap torque was not consistent in batches producing disproportional pressure on the liner with inconsistent sealing.

Cause Analysis

We made inspections, measurements, and found two primary reasons:

• Minor variations in the diameter and roundness of the finish of the neck had an influence on the compression of the liner.
• Lack of evenness in the cooling process resulted in slight ovality at the bottle mouth, which inhibits the integrity of the seal.

Solution

Improvement of Precision of Neck Finish.

We also recalibrated our rings, tightened our tolerance measures, and introduced go/no-go gauges to each batch to provide consistency in the neck dimensions.

Process optimization of Glass Bottles.

Fine-tuning of annealing curves and cooling rates was performed in the process of reducing ovality and internal stress. Bottles were subjected to pressure to make sure that they do not leak.

Packaging Adjustments

Shock-absorbent separators and protective carton inserts were introduced to avoid mechanical forces in the course of transportation and thus, to reduce the probability of leakage.

Custom 400ml Double Wall Glass Water Bottles	Custom 450ml 550ml Glass Water Bottles

Result

The leakage rates decreased more than 85 percent, the consistency of torque increased and the yield of production was stabilized. The Brazilian brand has come out with a lot of confidence by launching their sparkling and still water lines, and this must be a good confirmation that Yeboda is a trusted provider of glass bottles with high quality water bottles.