Tło klienta
Our client, a glass candle jars importer in Spain, consists of several mid-to-high-end fragrance brands in both Barcelona and Madrid. The new artisan candle series of their brand required them to have a frosted glass candle jar with a debossed geometric pattern and a natural bamboo lid.
They made a custom design choice because the Spanish home-fragrance market has changed to eco-aesthetic packaging. A frosted finish gives the product a soft touch while the geometric embossing helps the jar to have a unique look just like the other eco-friendly products on the shelves of boutiques. Their bamboo lid is perfectly in line with their sustainability-focused branding.
Mosteb was their choice because of our:
- Good custom mold development feature
- Consistent bulk production with clear frosting
- Capability of glass jars and making lids to be supplied from one place
- The fast feasibility reports and the transparent updates that made up the top notch professional engineering team
Wyzwania
Ten szklane słoiki na świece importer experienced two realistic problems during the pre-production and pilot shipping phases:
- Inconsistent Frosting Density:As some jars looked a bit more transparent than others, the differences became very visible when the cans were displayed as a set.
- Bamboo Lid Fit Tolerance Issues:In some cases, lids fitted too tightly due to micro-variations in the diameter of the jar opening thus causing usability problems for filling the candle.
Analiza przyczyn
Technical team carried out the thorough analysis.
After the investigation of the frosting inconsistency, the team found that the reasons for that were:
- Unequal spray angles during frosting application
- Changing drying temperatures were to blame for the variation in surface haze
We found the lid-fit problem to be resulting from the following:
- The slight differences during the cooling led to expansion of the mouth being different
- The bamboo lid producer had a tolerance range that was too narrow for the handmade wax-pouring process
Mosteb to fix the issues:
- Changed the spray pressure and angle for five rounds of frosting tests
- Performed thermal scan measurements to monitor the deformation caused by cooling
- Liaised with the lid supplier and changed the silicone ring compression level
- Made the Spanish client aware of the progress through regular updates and photos
Rozwiązanie
- Standardized Frosting Procedure:It was the fixed spray-distance protocol that they introduced and for uniform haze, they could ensure the work of the adjustable nozzle holders.
- Temperature-Controlled Drying Tunnels:The newly introduced mid-line step for temperature control made the frosting curing process more reliable.
- Re-engineered Jar Mouth Tolerances:They changed the mold’s upper-rim angle and the cooling cycle was controlled to stabilize the mouth diameter.
- Optimized Bamboo Lid Design:Working with the lid manufacturer, they slightly increased the tolerance and more flexibly fitting the silicone ring for the natural lid material they used.
Wynik
The importer realized the following achievements in just one cycle of production:
- Almost all the jars, i.e., 98%, had uniform frosting which passed their visual inspection standard
- Great customer satisfaction due to proper lid fit and a zero complaint rate
- Their environmentally-friendly candle line was successfully launched in a number of Spanish fragrance boutiques
As a result, the importer committed to a 12-month supply agreement with Mosteb and increased the holiday candle jar orders to include colored jars.
