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Case Study: Custom 500ml Slim Neck Glass Beverage Bottle for a Czech Republic Small Company

From Cracked to Commercial: How Roetell Solved a Slim-Neck Bottle Issue for a Czech Brand

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Client Background

Our client, a micro-enterprise based in the Czech Republic, specializes in producing small-batch, self-canned beverages. To support their local distribution, they required a custom 500ml glass bottle with a slim neck design that could reflect their artisanal brand identity.

Challenge

Although the bottle appeared simple in structure, issues arose during the initial sampling stage. The long, narrow neck exhibited a crack line, a structural flaw that could worsen during the hot-filling or capping process. This posed a risk of breakage, making the design unsuitable for commercial use without refinement.

Root Cause Analysis

  • Excessive cooling rate in the neck area during molding
  • Uneven glass distribution caused by poor air pressure balancing during the blowing phase

These factors led to internal stress concentration, especially around the transition point between the neck and shoulder.

Our Solution

To solve the problem, Roetell applied the following technical improvements:

  • Adjusted the mold design to create a more balanced neck-to-shoulder ratio

  • Optimized the cooling system to ensure gradual temperature reduction

  • Modified the blow molding pressure to improve glass wall consistency in the neck area

Additionally, we ran multiple trial productions to ensure the issue was fully resolved under mass production conditions.

Result

After implementing these changes:

  • The crack issue was eliminated

  • Bottle durability passed internal stress and pressure tests

  • The final design maintained the slim-neck aesthetics requested by the client

  • The bottle was approved for bulk production and successfully delivered

How We Do It

  • In-house mold engineering team optimized the structure

  • Quality control applied cold-end and hot-end inspections

  • Production line adapted for custom-form bottles

  • Delivered over 10,000 bottles on time with consistent quality

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Reliable Glass Bottles, Jars, Containers Manufacturer | Roetell