Integrated Process Optimization and Defect Analysis to Minimize Glass Jar Breakage in Acidified Gherkin Packaging Lines

Abstract

Glass packaging plays a pivotal role in maintaining the safety, integrity, and market quality of acidified gherkin products. However, frequent glass jar breakage during processing and handling presents a critical operational and sustainability challenge in pickle manufacturing lines. This study was conducted at Global Green Company Limited, Bangalore, to identify, analyze, and minimize glass jar breakage through an integrated processoptimization framework. Breakage data were collected across two production lines and four critical points—pasteurizer outfeed, dud detector, downing area, and conveyor system. Quantitative evaluation revealed higher defect incidence in large-capacity jars (1400–2000 ml), with thermal shock and mechanical vibration being the most significant contributors. Implementation of corrective measures, including gradual cooling, conveyor synchronization, torque calibration, and operator retraining, resulted in an average 51.7% reduction in breakage, confirmed statistically (t = 3.49, p <0.05, Cohen’s d = 1.56). Post-intervention, the mean defect rate declined from 7.3% to 3.52%, improving line efficiency and reducing waste generation by 35%. The findings establish that systematic process optimization combining root cause analysis and engineering controls can effectively enhance packaging integrity, economic performance, and sustainability in glass-packaged food manufacturing.