Manufacturing Upgrade for Superior Quality Squeeze Bottle Caps

A leading manufacturer of high-end silicone travel bottles was facing challenges with the squeeze bottle cap. Their silicone travel bottles were popular for being lightweight and durable, but as demand increased, the limitations of their bottle caps became evident. The client needed an efficient, cost-effective solution to improve production quality and streamline manufacturing.

Challenges Faced by the Client

1. Leakage Issues: 

The manual assembly process for silicone valves led to frequent misplacements, resulting in a 5% defect rate and increased customer complaints.

2. Production Inefficiencies & High Costs: 

Manual assembly caused low production capacity, with lead times extending to 30-45 days. Limited mold cavities further raised unit costs.

3. User Experience Problems: 

The existing silicone valve had slow air recovery, making it difficult to squeeze out liquid. Additionally, the butterfly clasp was prone to breakage, and the cap lacked a secure clicking sound when closed. Under high pressure, the cap often burst open.

Our Innovative Solution

1. Automated Production for Precision and Efficiency

• Smart Assembly & Dual Inspection System: We replaced manual assembly with a fully automated production line, integrating CCD vision detection and physical sensors to detect missing silicone valves in real time. This reduced the defect rate to below 0.01%.

• Enhanced Productivity & Cost Reduction: Automation increased production efficiency by 200%, cutting lead times to just 15 days. By upgrading to 8-cavity molds, unit costs dropped by 25%. Additionally, we offered a "2-year, 5-million-unit mold cost refund" policy to help our client operate with minimal investment.

2. Structural Enhancements for Better Performance & User Experience

• Reinforced Butterfly Clasp: We used high-transparency, high-elasticity plastic and redesigned the hinge structure, ensuring durability even after 10,000 folding cycles—a 10x improvement.

• Improved Seal & Click Mechanism: By optimizing the depth of the locking groove and the elasticity of the snap-fit, we ensured a crisp “click” sound when closing. Pressure simulations confirmed that the new cap could withstand high forces without bursting.

3. Breakthrough in Silicone Valve Technology for Leak-Proof & Smooth Dispensing

• LSR (Liquid Silicone Rubber) Injection Molding: We developed a high-precision cross-slit silicone valve and tested five different hardness and cut-size combinations. The final design—a 30° hardness valve with a 5.5mm x 5.5mm cross slit—improved air recovery speed by 40%, enabling smooth liquid flow without leakage.

Results & Value Delivered

• Superior Quality: Defect rates dropped from 5% to 0.01%, reducing after-sales costs by 80%.

• Cost Efficiency & Market Expansion: Unit prices decreased by 25%, and annual production capacity exceeded 10 million units, allowing the client to gain a competitive edge.

• Enhanced User Experience: End users reported effortless squeezing and reliable sealing, increasing repeat purchases by 35%.

  
  

Client Feedback

"YEJIA provided end-to-end support, from structural design to automated production, not only solving our immediate challenges but also elevating our product competitiveness to the next level!" — Client's Production Director

Why Choose Us?

With deep expertise in precision plastic and silicone components, we combine cutting-edge technology with exceptional service. From mold development to automated manufacturing and quality control, we provide one-stop solutions to help clients achieve product upgrades and business growth. Contact us today to experience next-level smart manufacturing for leak proof squeeze bottle caps!