The epidemic made the plastic commodity industry jumped another level, lots of factories got very good profits to invest more facilities to expand the capacity.
However, there are still many small factories use labor to finish all assemble works. Some clients lost much because of such poor quality control.
You need to be cautious when choosing lotion pump and trigger sprayer manufacturer for your next product
Lotion pumps and trigger sprayers are widely used in retail containers for many consumer products across different industries. The large amount of demand for the lotion pumps and trigger sprayers around the world has created a market situation where supply is increasing as many manufacturers enter the market at the same time. This means that there is no shortage of strong brand manufacturers in any industry, alongside some small-scale factories with weak technical strength.
For example, the current lotion pumps on the market generally include a pump chamber, pump beads, return springs, suction plugs with upper and lower pump rods, lock caps, and lock bottle caps. That’s a lot of small components and it is challenging to manufacture and assemble them all on time.
Since many lotion pump factories are not fully equipped with fully automated production lines, the product components of many manufacturers are assembled by hand. Here are three reasons why manual production and assembly is not a good idea…
1. Manual Assembly Requires a Lot of Resources
Manual assembly not only requires a lot of manpower, but also requires a large physical space to work in. For manufacturers, this is a disadvantage since you have to think of the extra costs of renting additional space and paying more staff. Often this cost is passed on to the buyer making the product more expensive.
2. Manual Assembly is Takes a Lot of Time
If you need to get your products shipped to you on time, then manual assembling of products is not for you. Because it is done by hand, manually assembling lotion pumps and trigger sprayers is is time consuming leading to delays in shipping your product.
3. Manually Assembled Products May Have Uneven Quality
Assembling products with small components manually is too inefficient. It is easier to make mistakes and produce defective products when you are assembling the tiny components in the trigger sprayers or lotion pumps by hand. This can make the quality of manufacturers’ products uneven, as some pump sprayers will work well, and others will not.
Normally, the uneven quality you may face if they assemble by labor:
- Loose nozzle
- Loose gasket
- Poor Airtightness— leakage
If you need to buy dispending products like trigger sprayers and lotion pumps, you need to know how to make the right choice. Experienced purchasers know that, product quality and quality service delivery depend on the strength of the factory to quickly deliver quality products orders using automated production lines.
Features of Automated Production Lines
Some manufacturers have inefficient and outdated automated production lines. Some of the features you should be looking out for when you consider a manufacturer’s production line include:
- The Output:
Products produced by automated production lines are to have a reliable amount of output.
- Up-to-date Technology
For the best results, the manufacturer you choose should have a product design process and technology that is advanced, stable, and reliable. It is best if the technology in use is the best available.
- How does it improve productivity?
Large-scale, mass production, rely on automatic lines to improve labor productivity, stability and product quality.
The image below is an example of a fully automated lotion pump production line
Lotion pump Production Line
Main Assembling Parts:
Up stem, piston, Down stem, Housing, Bead, Spring, Coil, Lock cover, Gasket, Spray nozzle.
Main assembling components:
Piston assembling machine→Spray nozzle & piston subassembly & coil & glass bead assembling machine→Spray nozzle subassembly & & coil & body assembling machine→4pcs one-time testing & locking machine→Tube-inserting machine
Key Feature: A single or linking machine can work steadily
Speed: 150 ppm above
This assembly line meets the European operating standards. The parts are automatically loaded by the feeding system, and the production line has functions such as parts assembly, performance testing, and automatic rejection of unqualified products, ensuring product quality and productivity, saving human resources, and adapting to large-scale factory production.
Product Machine Inspection is More Secure
The lotion pump is an important part of the lotion container, and there is a lot of social demand for it. The market for lotion pump manufacture is also big enough. Because of all this, there is clearly a need for mass producing the lotion pump.
However, during the production process, there will be problems such as stains on the surface and upside down of the tail pipe. Therefore, strict surface inspection is required to ensure its quality and enhance its commercial value and use value.
Most of the traditional detection methods are based on manual detection. The manual detection method is susceptible to factors such as the thoughts, current mood, eye fatigue, experience difference, work intensity and other factors of the examiner, which reduces the reliability of the detection results, and ultimately leads to low detection efficiency. Low detection efficiency is not conducive to product production. Machine detection is a better way to be sure of the integrity and quality of the product and the assembly line. Detection automation effectively solves the above problems and ultimately improves product quality.
Lotion Pump Function Test: Which Functions Are Tested?
Generally, the lotion pump has about 6-7 injection parts (some products have 4 – 5 injection parts), plus other accessories, such as glass beads (plastic beads, or valve discs), springs, straws, gaskets, etc.
In total, it is about 9 – 12 parts. But the basic functions of lotion pump products have not changed significantly. The basic functions of lotion pump are:
1. To Seal the Container
No consumer will buy a bottle of a product whose contents have leaked or is leaking to the surface of the bottle.
After the lotion pump and the bottle are filled and packaged, the sealing function is one of the most important requirements to ensure that the bottled product is stored and transported. Sealing the lotion pump is a bit complicated, and we will talk about it in detail later on.
2. To Pump the Content of the Container Out
The second important and basic feature of the lotion pump is that it can pump the same volume of material and liquid every time for consumers to use. This pumping function is also one of the important requirements of the lotion pump.
For the manufacturer, here are some of the steps to follow to confirm if this function is working properly.
- Turn on the lotion pump
- Press the head down to the end of the stroke
- Block the liquid inlet of the body (cylinder Housing) with the finger of the other hand, and then release the button.
If the head makes it rebound naturally, and the skin on the surface of the finger feels sucked (commonly known as “suction”). Then you can confirm that the pump is working. You can even hang the lotion pump upside down on your finger.
This is one of the main ways for manufacturers to determine whether the pumping function is intact. With the improvement of the precision of the pressure electronic sensor valve, this “suction” can also be detected with fully automatic equipment.
Lotion pump with good suction
3. Pump Output (How Much Output is Pumped Out)
The pump output refers to the volume of the liquid that is pumped out each time the consumer uses the emulsion pump. Follow the steps below to test it.
After the lotion pump is filled with liquid,
- Press the head to the end of the stroke (stroke is H) to pump the volume of the liquid.
- The pumping volume is calculated using this formula, V=πD2*H/4.
- Because the pumping volume of the lotion pump is relatively small, 10 consecutive times are often used as a detection process, and the average is taken.
- Some companies use grams (g) as the unit for testing.
There are two factors to take note off:
(1) Water is used as the medium when testing
2) The fluidity of the material is not good, and the measuring cylinder cannot be read when the material liquid is used as the medium.
The density of the material liquid needs to be considered when setting the pump output standard.
4. Air Pressure Times.
Air pressure times refers to the total number of repetitions since the consumer opened the button and blocked the button until the first time the liquid was discharged.
In theory, it means that after the lotion pump is fully opened, the insurance factor will increase from 1.1 to 1.3 from when the manufacturer sets the nozzle from the nozzle to the end of the straw.
The main factors that influence this are the thickness and length of the straw, as well as the cumulative tolerances of the various parts of the lotion pump.
When the lotion pump is in use, some parameter settings are mainly based on consumer experience. The main parameters are as follows:
l Press the head to unscrew the torque.
For a lotion pump with a screw head and a screw thread, consumers will first unscrew the head when using it, so this parameter should not be too large to prevent excessive resistance from causing difficulties for consumers to open. But it should not be too small, which will cause the head to loosen during transportation and affect the sealing function. The conventional control parameter is 3~10Kgf·cm.
l Press the head down pressure.
The minimum force required to press the head down to the end of the stroke (also known as the minimum down force). When detecting an empty pump or using water as a medium, it refers to the spring force at the end point of the head + the frictional resistance between the piston and the body.
The influencing factors of the pressing head down pressure during discharging liquid will increase because of:
- The viscosity of the material liquid.
- The fluidity of the material liquid.
- The size of the liquid outlet channel affects the composition of the material liquid Resistance.
- The speed of depression; etc.
The high viscosity, low fluidity, and high pressing speed of the material liquid will cause the pressure to increase under the head. Generally, 90% of the entire stroke of the lower pressure is the test value, and both parties confirm the speed of the lower pressure.
5. Press the Head to Determine the Rebound time.
The rebound time is the time it takes for the head to naturally rebound to the top dead center when the head is released after it is pressed down to the end of the stroke.
The factors that influence rebound time are:
(1) The elastic force of the spring
(2) The frictional resistance between the piston and the inner wall of the body
(3) The viscosity of the material liquid
(4) The fluidity of the material liquid
(5) The size of the outlet channel affects the composition of the material liquid Resistance; wait. Generally, 1~3 seconds is the criterion.
Packbien pays attention to product quality. The parts of the fully automated production line are automatically loaded by the feeding system. Our production line has functions such as parts assembly, performance testing, and automatic rejection of unqualified products, ensuring product quality and production capacity, and is a reliable partner for global buyers.
To further ensure top-notch quality, every lotion pump and trigger sprayer produced by Packbien must go through multiple steps before we are ready to ship your order.
- First, we carry out the appearance inspection to ensure that the appearance is good, no scratches, no black spots. We make sure that the product is clean and hygienic.
- We make sure that the number of first pumping presses must be less than or equal to six times.
- The liquid pumped out by the plastic pump head must be even and meet the specifications every time, and a strict pumping volume test will be performed.
- The pump head will fill the liquid with the bottle and test it in a vacuum environment to ensure that it does not leak or overflow.
- The pump head is subjected to a backflow test to see if it will flow back to the nozzle.
- The pump head undergoes strict suction test.
- Gasket thickness detection of pump head
- Tube length test of pump head.
- All accessories are complete.
It is only when our product has passed all of these quality assurance tests that we deliver it to our global customers. Our stance on uncompromising quality is part of what how we design and produce our products. As a customer, we know that you need only quality products and we go the extra mile to design and develop just that for you!
Feel free to reach out to us and a representative will be on hand to guide you through the production process.