Client Background
Small mason jar packaging was the perfect fit for our client, an environmentally conscious brand of boutique jams made in Canada. They produce no less than seven different types of fruit jams with 100% organic and locally sourced berries. With climate change in focus, making smaller portions of their jams seemed the best choice to the brand. Therefore, after the brand’s product line grew significantly, the company decided to custom-make a small mason jar that would not only match their image of a high-end brand but also waste less. In addition to creating a jar suitable for fruit jams, the brand also had the ideal target consumers in mind—cafés and gift hampers. They decided that Mosteb was the right choice because of our accurate glass molding, strong customization capability, and proven track record in producing branded glass containers with consistent clarity and durability.
Challenge
Two major technical issues were detected during development:
- Embossing or Logo Clarity:As the molding area of the jar was limited to a very small part of the side surface, it was almost impossible to get a crisply defined and readable logo of the brand at glass molding. Small and slight variations of mold temperature or pressure could result in a slight blurring of the trademark design.
- Weight Balance During Filling:Because the jar had a small base and was lightweight, even the smallest and most insignificant imbalances at weigh-in could trigger a chain effect of the jars tilting or wobbling at the production line, which in turn resulted in the lessening of efficiency and even spillage.
Cause Analysis
The technical department did an in-depth investigation and found out two main issues: the depth to which the logo was being engraved on the mold was not sufficient for small-format embossing, and the thickness of the jar’s bottom was a bit off causing stability problems. To solve these problems, we did a lot of prototype tests varying mold depths and changing the shape of the base while at the same time ensuring that the jar’s aesthetic proportions were preserved. We kept our communication with the client’s packaging engineers at a high level throughout the procedures to make sure that every alteration met branding and functional requirements.
150-1000ml Glass Mason Jar Storage
150-1100ml Round Glass Mason Jar
Solution
- Precision Mold Optimization:The mold engraving process was improved with laser-assisted carving to control the depth and assure the embossed logo stayed sharp even at a small scale.
- Bottom Structure Adjustment:The base was redesigned with a gentle concave reinforcement ring to facilitate weight distribution and thus to prevent the jar from tilting during filling.
- Advanced Quality Control:Put in place automated optical inspection for logo clarity and base symmetry to ascertain every batch conformed to visual and dimensional standards.
- Stability Testing Simulation:The stability of the jars was tested and improved during the simulated conditions of a conveyor-line prior to mass production.
Result
The small mason jar was a success story both from an aesthetic and functional point of view. The embossed brand logo was well-defined and detailed which in turn gave the product higher chances of being noticed on the shelves. Also, because the filling area was stable, it was free from any incidents of spills or wastage. This resulted in a 30 percent increase in the packaging line efficiency as well as notable visibility at retail by the client after launch. The cooperation not only helped Mosteb to be recognized as a dependable partner for luxury glass packaging, but also enabled the client to create a distinct identity in the competitive artisanal jam market.
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