The Production Journey: 7 Stages
Stage 1: Raw Material Receiving
Virgin PET/HDPE/PP granules arrive in 25kg bags from Sinopec and PetroChina. Material certificates verified against order specification. Granules stored in climate-controlled silos to prevent moisture absorption (critical for PET).
Stage 2: Injection Molding (Caps, Closures, Pump Parts)
Granules fed into injection molding machines (80-320 ton clamping force). Heated to 230-280°C (varies by plastic type). Injected into steel molds at high pressure (800-1,200 bar). Cycle time: 15-30 seconds per shot. Multi-cavity molds produce 4-16 caps per cycle.
Stage 3: Blow Molding (Bottle Bodies)
PET preforms (test-tube shaped) heated in infrared oven to 100-120°C. Stretch blow molded: rod stretches preform while high-pressure air (30-40 bar) inflates it into bottle mold. Cycle time: 8-15 seconds. HDPE/PP bottles use extrusion blow molding — parison extruded, mold closes, air inflates.
| Process | Material | Cycle Time |
|---|---|---|
| Injection Stretch Blow Molding (ISBM) | PET | 8-15 sec |
| Extrusion Blow Molding (EBM) | HDPE, PP | 10-20 sec |
| Injection Molding | PP (caps, pumps) | 15-30 sec |
Stage 4: Assembly
Bottle body + spray pump + dip tube + cap assembled on automated lines. Dip tube cut to length, inserted into pump. Pump screwed onto bottle. Cap applied. Speed: 2,000-5,000 units/hour per line.
Stage 5: 100% Leak Testing
Every unit passes through vacuum leak tester: -0.05 MPa for 5 seconds. Cameras monitor for air bubbles. Failed units automatically rejected to rework bin. Zero tolerance for leaks.
Stage 6: Printing & Decoration
Silk screen printing: 1-3 colors applied through mesh screens, UV-cured. Hot stamping: metallic foil heat-pressed. Speed: 2,000-4,000 units/hour. Quality check: random sampling for print alignment and adhesion rub test.
Stage 7: Packaging & QC Inspection
Individual poly bag, bulk packed in export cartons. AQL 2.5 sampling inspection: visual, dimensional, functional. Cartons labeled with PO number, quantity, destination. Palletized, stretch-wrapped, ready for container loading.
FAQ
How long does production take?
Standard stock products: 5-10 days. Custom color/logo: 20-25 days. Custom mold: 50-65 days including mold fabrication. Rush orders available at +15-20% surcharge.
Can I visit the factory?
Absolutely. Desikyspray welcomes factory visits. Ningbo airport is 1 hour away. We can arrange airport pickup and hotel. Seeing the production line builds trust that no video call can replace.
Related Articles: How to Choose a Supplier on Alibaba · OEM Custom Manufacturing Guide · Samples Guide: Testing & Approval · Cosmetic Bottle Wholesale Guide