Packaging Pitfalls: Top 3 Watchouts for Closures with Scott Roman
Sometimes overlooked, closures play an essential role in packaging, impacting both product integrity and application experience. Whether threaded caps or cosmetic pumps, the closure must provide a reliable seal, functional convenience, and aesthetic attractiveness. Below, we outline the top three pitfalls associated with closures, the potential impacts on your brand, and the ways to mitigate them.
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1. Dimensional Interference Causing Ineffective Seal on Threaded Closures
Dimensional interference can compromise the sealing capability of threaded caps, potentially resulting in product leakage and consumer dissatisfaction.
Implications
- Product leaks during storage or transport.
- Negative consumer experiences and product returns.
- Potential brand damage due to perceived poor quality and formula degradation.
How to Avoid: Analyze the H dimensions on both cap and container technical drawings. Conduct a detailed stack-up analysis to ensure the cap does not bottom out on the container shoulder, accounting for liner compression and all part tolerances. Confirm consistent sealing performance through rigorous testing and dimensional validation.
2. Insufficient Fit of Cap to Pump Allowing Filled Package to Fall When Picked Up
A poorly fitting closure that cannot securely engage with the pump mechanism can result in critical product usability issues including accidental dropping or spillage of product when handled, increased returns, and decreased brand sentiment.
How to Avoid: Starting with the diameter dimensions from the cap and pump technical drawings, analyze the friction or snap force to ensure the cap securely holds at least twice the weight of the filled package. Evaluate the H dimensions of the container and pump for proper stack-up, preventing the cap from bottoming out against the shoulder of the container. Ensure gasket compression and part tolerances are accounted for in your analysis.
3. Decoration Adhesion or Compatibility Failures
As closures increasingly contribute to brand differentiation, ensuring robust decoration adhesion and compatibility has become vital. With expanding supplier decoration capabilities, the risk of decoration failures—such as peeling, fading, or chemical deterioration—can greatly undermine new innovations.
Implications
- Adhesion failures result in decoration peeling or damage without direct product contact.
- Compatibility failures due to chemical interactions degrade decoration appearance over time.
How to Avoid: All decorated closures, including those with hot-stamping, silk-screening, heat-transfer labels, pad-printing, and vacuum-metallizing, should undergo extensive testing for proper adhesion and chemical compatibility with the formula. Address any issues by adjusting curing properties, dwell times, ink or lacquer compositions, exploring alternative foils, or applying a UV-cured clear topcoat to protect decoration integrity.
By proactively addressing these critical risks—dimensional interference, secure fit, and decoration integrity, you can ensure your closures deliver reliable functionality and appealing aesthetics.
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.
Scott Roman | Ventus Packaging Solutions LLC |Sroman@ventuspack.com
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