Bottle Caps And Closures Reusable Caps For 5-Gallon Water Bottles

1. Product Overview

2. Product Specifications

2.1 Material

• Core Material: Food-grade polypropylene (PP)
  • Feature: BPA-free, non-toxic, odorless, and resistant to corrosion from water and common cleaning agents.
  • Temperature Resistance: -20°C to 120°C (-4°F to 248°F), suitable for both cold and warm water storage.
• Sealing Component: Food-grade silicone gasket
  • Feature: High elasticity, excellent leak-proof performance, and no deformation after long-term use.

2.2 Dimensions

2.3 Performance

• Leak-Proof Rate: 100% leak-proof when properly installed (tested under 0.5MPa water pressure for 24 hours).
• Reusability: Can be reused up to 500+ times with proper cleaning and maintenance.
• Load-Bearing Capacity: Withstands a top load of 5kg without cracking (suitable for stacking 5-gallon bottles).
• Certifications: Compliant with FDA (US), LFGB (EU), and GB 4806.7-2016 (China) food contact material standards.

3. Manufacturing Process Flow

3.1 Raw Material Inspection & Preparation

1. Source food-grade PP pellets and silicone raw materials from certified suppliers (with batch-specific certification documents).
2. Test raw materials for BPA content, toxicity, and mechanical properties using a third-party laboratory (SGS or Intertek) to eliminate substandard materials.
3. Dry PP pellets at 80°C for 2-3 hours to remove moisture (prevents bubbles in the final product).

3.2 Injection Molding (for PP Cap Body)

1. Feed dried PP pellets into a precision injection molding machine (clamping force: 1200kN).
2. Set molding parameters: Temperature (barrel: 180-220°C; mold: 40-60°C), injection speed: 50-70mm/s, holding pressure: 50-70MPa.
3. Mold the PP cap body with integrated thread structures (matches standard 5-gallon bottle mouth threads) – cycle time: 30-40 seconds per unit.

3.3 Silicone Gasket Molding

1. Mix silicone rubber with food-grade vulcanizing agents (ratio: 100:2) and stir uniformly.
2. Use compression molding to form silicone gaskets: Temperature: 160-180°C, pressure: 10-15MPa, curing time: 3-5 minutes.
3. Trim excess flash from gaskets to ensure smooth edges.

3.4 Assembly

1. Automatically assemble silicone gaskets into PP cap bodies using a robotic assembly line (accuracy: ±0.1mm).
2. Conduct a manual spot check to ensure gaskets are fully seated and not misaligned.

3.5 Quality Inspection (QI)

1. Leak Test: Submerge 5% of each batch in water and apply 0.3MPa pressure – no bubbles allowed.
2. Dimensional Test: Use a coordinate measuring machine (CMM) to check 3% of products for compliance with size specifications.
3. Material Test: Randomly select 1% of products for BPA and toxicity testing every month.
4. Durability Test: Simulate 500 opening/closing cycles on 2% of products – no cracks or gasket deformation permitted.

3.6 Packaging

1. Clean qualified caps with food-grade disinfectant and dry them.
2. Package in individually sealed PE bags (food-grade) to prevent dust and contamination.
3. Place packaged caps in corrugated cartons (with anti-collision foam inserts) – 500 caps per carton.
4. Label cartons with batch number, production date, and certification marks (FDA, LFGB) for traceability.

4. Customer Customization Services

4.1 Customizable Options

4.2 Customization Process

1. Consultation: Clients provide customization requirements (color, logo, functionality) and quantity.
2. Sample Development:
   • Create a 3D design draft within 2 working days for client approval.
   • Produce 5-10 physical samples within 5-7 working days (sample fee: $50-$200, refundable upon bulk order).
3. Approval & Production: Start bulk production once clients confirm samples (production lead time: 10-15 working days for orders under 10,000 units; 20-25 days for orders over 50,000 units).
4. Quality Assurance: Conduct 100% inspection on customized products to ensure logos/functions meet requirements.

4.3 Minimum Order Quantity (MOQ) for Customization

• Standard color/logo customization: MOQ 500 units.
• Functional customization (anti-theft ring, vent valve): MOQ 2,000 units.
• Special material customization (high-temperature/UV-resistant PP): MOQ 5,000 units.

5. Application Scenarios

• Water Delivery Services: Securely seal 5-gallon bottles for door-to-door delivery (reduces leakage during transport).
• Corporate/Office Use: Reusable option for pantry water dispensers (cuts down on disposable plastic waste).
• Schools & Hospitals: Food-grade, non-toxic design ensures safety for students and patients.
• Outdoor & Camping: Durable and leak-proof – suitable for storing water in outdoor settings.

6. Quality Assurance & After-Sales Service

• Warranty: 1-year warranty against material defects (free replacement for defective products within the warranty period).
• After-Sales Support: Respond to client inquiries within 24 hours; provide technical guidance for installation and maintenance.
• Traceability: Each batch can be traced back to raw materials and production steps via the batch number on cartons.