Packaging Pitfalls: Top 3 Watchouts for Glass Jars & Bottles
Packaging is a consumer’s first touchpoint with your product and is often the deciding factor in a purchasing decision. Great packaging can create a positive, memorable experience, while poor packaging can leave consumers frustrated, disappointed, and hesitant to trust your brand again.
When it comes to glass jars and glass bottles, there are a few crucial risks that can affect quality, durability, and consumer satisfaction. Below, we’re breaking down the top three packaging watchouts for glass containers, what these risks could mean for your brand, and—most importantly—how you can avoid them to ensure your packaging creates the right first impression.
Starting a new project? Schedule a meeting with a Packaging Pro to avoid common packaging pitfalls for your component types.
1. Glass Defects
Glass defects are one of the most common issues encountered in packaging, but they’re often preventable with the right approach. These defects can pop up during the manufacturing process, leading to some major issues down the road.
Common Defects to Look Out For
- Thin glass at the shoulders – This is a weak point that can lead to cracks during shipping or when filling.
- Uneven glass distribution at the heel – You might end up with one side thicker than the other or a wavy bottom, making the bottle unstable.
- Cocked neck finish – The neck isn’t strong enough to support the bottle, which can cause it to crack or deform during the manufacturing process.
- Folds, Washboard Marks, Orange Peel Marks, Seeds - Visible markings on the glass that will impact your product’s aesthetics
Implications
Defects like cracks or breaks during transit, instability during filling, and potential hazards for consumers are all strong possibilities. In addition to potential recalls, defective glass can harm your brand’s reputation, generate negative product reviews online, and increase costs.
How to Avoid
- Collaborate with your supplier’s Quality Assurance (QA) team to set clear Acceptable Quality Limits (AQLs) for each possible defect. Set thresholds for critical, major, and minor issues (for example, Critical 0.40, Major 1.0, Minor 4.0).
- Use range boards and routine inspections to monitor for common defects like folds, seeds, and washboard marks to ensure consistency and safety in your glass packaging.
2. Insufficient Overflow Capacity (OFC)
Overflow capacity (OFC) might not sound like a big deal, but when a container’s OFC is too low, it can throw off your label claims and lead to a misalignment with consumer expectations.
Implications
Mislabeling your product’s volume can result in regulatory penalties and lost consumer trust if the packaging appears underfilled.
How to Avoid
- Work with a packaging pro to review the OFC on your component’s technical drawing
- Deduct glass tolerance, any displacement from interior components (eg. pumps, droppers, wiper, rod & applicator, or sealing disk), necessary headspace, and filling equipment tolerance.
- The remaining volume gives you your legal label claim in milliliters or fluid ounces. If you’re claiming by weight instead of volume, convert the volume calculation into grams or ounces using your product's specific gravity.
3. Decoration Adhesion or Compatibility Failures
Your brand’s packaging design is a critical part of the customer experience, but decoration failures can ruin that first impression. Adhesion issues, where the decoration peels off without product contact — or compatibility failures, where the product itself degrades the design — can cause major headaches.
Implications
Poor adhesion can make your packaging look defective and lower its perceived value. Compatibility failures may occur over time as your product interacts with the decoration, leading to damaged packaging and customer complaints.
How to Avoid
- Work with your supplier or testing partner to test all decoration methods (including silk-screening, hot stamping, heat-transfer labels, pad-printing or spray coatings) for proper adhesion to the glass surface.
- Ensure the decorations are compatible with the product by conducting interaction tests.
- If issues arise, adjust curing properties / dwell times or ink compositions, or add a UV-cured topcoat to isolate the decoration from interacting with the formula
By tackling these three key risks—glass defects, overflow capacity, and decoration issues—you’re not just protecting the quality of your packaging, you’re also creating a standout experience for your customers.
Ready to Source?
That rounds out the top three packaging watch outs for glass containers. Looking to source glass packaging? Browse the Impacked marketplace today to find a component:
About the Author
Scott is an award-winning package development professional with 30+ years of multi-industry experience. A seasoned packaging expert with extensive experience in beauty and cosmetics, Scott led packaging innovation for the makeup category at Estée Lauder, driving projects from concept to launch in lip, foundation, primer, and makeup / skincare hybrid packaging. Before that, he directed package development for Tom Ford Beauty, overseeing luxury packaging in fragrance, makeup, and skincare. With expertise spanning all cosmetic packaging materials and processes, Scott has a strong background in project management, packaging development, and on-site production across global facilities.
