Weight Optimisation For Glass Jar

Packaging Engineering & Development
The aim was to optimize 500g glass jar bottle weight without changing its structural loading capacity compared to its existing design

Glass has many properties that make it an ideal choice for bottles and for packaging many other foodstuffs but, whilst it is an inherently strong material, it is also a brittle one.

Forces acting on hollow items such as containers can simultaneously produce both compressive and tensile stresses. A force that produces compressive stress on the outer surface also produces tensile stress on the inner.

The study explains how and why a brittle material like glass fails. We have used simulation to get a clear idea of the stressed zone so we can remove the material from the less stressed zone area making it much lighter.

Major challenge was to understand the manufacturing workflow and what are the critical milestones/points that needs to be kept in mind while designing and engineering a new solution.

Manufacturing process workflow

Approach followed to reach a solution

Design approach workflow

Optimizing Process

To understand and calculate the major loading scenarios we understand their entire process from filling to storage and finally to transportation. Then after funnel down into three important load scenarios

1.Top load


3.Transport worthiness

Top load stress plot

Impact load

Transformational load


We iteratively simulate the above loading scenario for the base model until we get a refined final model with optimized weight without much change into the structural strength compared with the base results.

We were successfully able to reduce up to 15% of the actual weight of the bottle with a very negligible amount of change in structural strength.

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