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Discussion on sealing technology of bottle cap
The bottle mouth seal remains a challenging issue in the beverage industry. Many people have tried to come up with solutions, but the problem persists because the sealing is only done at the bottle’s opening, not along the threaded portion. From manufacturing to the moment a consumer opens the bottle, various factors can lead to contamination of the threads. For example, during the filling process of sugary or nutrient-rich beverages, liquid splashes onto the threaded area. Over time, bacteria and exposure to air cause mold and discoloration on the threads. Additionally, poor storage or transportation conditions can introduce dirt or moisture, especially if the product is stored in icy environments for long periods.
Consumers often find the thread area dirty after opening the cap. Once the cap is removed, there’s little they can do about it, so they’re left dealing with the issue. In terms of drinking habits, most people don’t use straws when consuming plastic bottled drinks. Instead, they drink directly from the bottle, which means any contaminants on the threads could enter their mouths. This is particularly concerning for children, who are more vulnerable to such issues.
Many beverage companies are aware of this problem and have implemented several measures to reduce contamination, such as adjusting filling levels, minimizing vibration during the capping process, and cleaning bottles before sealing. However, the issue still occurs occasionally, and current methods aren’t fully effective. For instance, hot filling requires full liquid level and overflow, which creates a contradiction in sealing. Sometimes, defective products account for over 1% of production, leading to internal recycling. Plus, contamination during transport and retail is hard to control, resulting in complaints that damage brand reputation.
Based on the analysis, the main issue lies in the lack of proper sealing around the threaded part of the bottle mouth. While some food packaging includes protective elements like rubber covers (as seen in certain porridge containers), these add-ons are not commonly used in plastic beverage bottles. They also tend to be costly and offer limited sealing effectiveness. So, is there a simple and cost-effective solution?
We propose an improved inner plug design that enhances the seal around the bottle mouth. There are two common types of seals: top-seal caps (single or dual-piece) and sealed inner plugs. The top-seal cap uses a gasket that deforms under pressure to create a seal, while the inner plug relies on an interference fit between its outer diameter and the bottle’s inner diameter. These methods differ in performance—gasket caps are better suited for pressurized bottles, while inner plugs are more common in low-pressure applications, such as hot-filled beverages.
From a production standpoint, inner plugs are easier to manufacture, less expensive, and maintain consistent resealing properties, making them popular in non-carbonated drinks. Importantly, the sealing effectiveness of the inner plug isn't dependent on the final tightening torque of the cap. In practice, the torque applied is mainly to prevent accidental loosening. Therefore, improving the inner plug design can effectively solve the thread contamination issue without significantly increasing costs.