Difficult to press or blocked opening
This is one of the most common problems, which usually occurs when the bottle cap structure design is unreasonable or the material hardness is too high. If the pressing area of the Disc Cap is too compact and lacks mechanical optimization design, users will feel uncomfortable when using it, or even cannot open it smoothly. Shaoxing Roman Plastic Co., Ltd. continuously optimizes the mold design in terms of bottle cap structure, improves user experience through reasonable opening angle and force point distribution analysis, and uses medium hardness PP material in material selection, taking into account strength and flexibility to ensure easy pressing and smooth opening.
Liquid leakage problem
The leakage problem is mainly concentrated in two aspects: the bottle mouth thread is not tightly sealed and the cap body is poorly assembled. Some low-quality products have insufficient thread precision control during the injection molding process, resulting in a small gap after the bottle cap is tightened, which is easy to leak when transported or placed on the side. Shaoxing Roman Plastic Co., Ltd. has more than 50 injection molding machines and a strict mold precision control system to ensure that each product has the same size. At the same time, it is equipped with 15 assembly and testing production lines to conduct batch-by-batch sampling of sealing to effectively reduce the risk of leakage.
Blocking and residual liquid accumulation
Some high-viscosity liquids such as creams and essences may accumulate liquid at the mouth of the plastic disc cap bottle after long-term use, causing blockage inside the bottle cap and affecting the liquid discharge effect. This is usually related to improper design of the liquid discharge aperture or insufficient material resilience. Shaoxing Roman uses variable-diameter guide groove design in the Disc Cap structure by sampling data from the formulas of customers in different industries, which not only prevents blockage but also facilitates cleaning, and is particularly suitable for lotion products.
The cap and bottle body fall off or loosen
This type of problem often occurs when the transportation vibration test fails or the assembly tolerance is not strictly controlled. Once the cap is loose during transportation, it is very easy to cause product contamination or customer complaints. Shaoxing Roman Plastic Co., Ltd. uses the transportation drop test as a standard process in the early stage of product design, and enhances the overall anti-seismic performance of the product by adjusting the bite strength between the bottle mouth and the cap. At the same time, automatic torque assembly equipment is introduced to ensure accurate assembly.
Chemical incompatibility and discoloration
Some Disc Caps may turn yellow, crack, or even release odors after contacting alcohol or acidic or alkaline ingredients due to the use of non-corrosive materials. Shaoxing Roman insists on using PP and PE materials certified by FDA and EU standards in material selection, and cooperates with customers to conduct pre-compatibility tests on their formulas to avoid quality accidents after product use.
Appearance defects and poor processing
Defects such as flash, shrinkage, color difference or uneven spraying directly affect the brand image. Shaoxing Roman has nearly ten years of surface treatment experience and is good at UV spraying, thermal transfer, silk screen printing, hot stamping, labeling and other process combinations. It can achieve personalized high-quality surface effects according to customer needs, and conduct a full appearance inspection through a strict QC process to ensure that the final shipped products are beautiful and consistent.
What to pay attention to when storing plastic disc cap bottles
The temperature and humidity control of the storage environment is crucial
Plastic disc cap bottle and bottle caps are mostly made of PP, PE, PET and other materials. Although they have good corrosion resistance and chemical stability, their physical properties are still affected by temperature and humidity. In particular, PP bottle caps are prone to softening and deformation in high temperature environments, while low temperatures may cause the material to become brittle, affecting the opening feel.
Shaoxing Roman recommends:
The storage environment temperature should be controlled between 5℃ and 35℃;
The relative humidity should be maintained at 40% to 70% to avoid moisture causing product packaging or label adhesion;
Do not expose the product to direct sunlight or near heat sources such as heating pipes and boilers.
In Shaoxing Roman's 13,000 square meters of modern factory area, the finished product warehouse is equipped with a complete constant temperature ventilation system to ensure that each batch of products is in good storage condition before leaving the factory.
Avoid heavy pressure and excessive stacking to prevent structural deformation
Although the Plastic Disc Cap Bottle has a compact structure design, the bottle body and bottle cap are still lightweight plastic parts. Long-term heavy pressure or excessive stacking may cause:
The bottle mouth is deformed, affecting the screw-on accuracy;
The cap body is warped, causing sealing failure;
The bottom is concave, affecting the standing stability and aesthetics.
Shaoxing Roman Plastic Co., Ltd. uses calculated and designed cartons and partitions for pressure-proof packaging of all products during daily shipments to avoid human damage during transportation and storage. In addition, the company has 15 automatic assembly and packaging lines, and each batch of products will undergo a stacking pressure test before packaging to ensure that the bottle body is straight and the cap has no warping edges.
Prevent pollutants from invading and maintain cleanliness
Since Plastic Disc Cap Bottle is mostly used for liquid products that come into direct contact with the skin, its cleanliness requirements are extremely high. If dust, oil stains or foreign matter in the storage environment invade the bottle or cap, it will not only affect the hygiene requirements during product filling, but may also cause consumer complaints during final use.
For this reason, Shaoxing Roman has set up an independent purification packaging area in the factory and strictly implements secondary dust removal measures before the product leaves the factory. We recommend that customers:
Store the product in a closed warehouse or a dedicated packaging room after receiving the product;
Reseal the packaging bag immediately after each unpacking;
Wipe the bottle mouth and cap aseptically or blow dust removal with wind before filling to ensure terminal cleanliness.
Reasonable batch management to ensure first-in, first-out
Although plastic bottle caps do not have an obvious shelf life like food, their physical properties will change slightly over time. To avoid problems caused by material aging, a scientific first-in, first-out (FIFO) management system should be established, and early arrival products should be used first.
Shaoxing Roman Plastic Co., Ltd. marks the production date and batch code on the outer packaging of each batch of products to facilitate customers to track storage and manage outbound shipments, which is particularly suitable for the refined management process of large filling plants and OEM companies.
Transportation protection: protect every kilometer from factory to warehouse
Many customers regard storage issues as the internal responsibility of the factory, ignoring the problems that may occur during transportation from the factory to the local warehouse, such as bumps and damage, temperature difference condensation, and moisture in the cargo box.
Relying on its geographical advantage of being close to the ports of Ningbo and Shanghai, Shaoxing Roman adopts multiple protection measures such as shockproof inner trays, wrapping films, and moisture-proof bags in export packaging. At the same time, it can customize pallet packaging methods according to customer needs to improve loading and unloading efficiency and transportation safety.
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