Is it possible to order custom bottle samples?

We can make samples, but to do so requires an investment from you of about US $7,000. This includes bottle molds and prototyping fees. Unless you plan on purchasing large volumes of the bottle in the future, ordering samples alone is not advised.

What is the minimum order quantity (MOQ)?

For custom superflint bottles, the required minimum order is one full 40-foot high cube container (40'HC - for more information refer to: http://en.wikipedia.org/wiki/Intermodal_container). For custom standard flint bottles, the MOQ is two full 40'HC containers. The actual quantity per container will depend on the size of the bottle and how it is packed.

Approximately how many bottles would fit in a 40HC?

Symmetrical 750ml bottles can fit approximately 24K if they are packed with boxes, or roughly 27K if they are packed in bulk. Irregularly shaped 750ml bottles can usually only fit approximately 21K if they are packed in boxes. Roughly 60K standard 12 oz. beer bottles will fit in a 40HC. If we order a full container, can we opt for partial shipment and keep the rest in stock for later? Generally, yes. The MOQ is the minimum we must order from the factory. It is not required that we ship this all at once.

How much does a set of production molds cost?

The base cost to produce a mold is roughly US $7,000 for a standard bottle. The greater the size and complexity of form, the greater will be the cost to produce the mold.

How long does it take to get the first order (for a custom bottle)?

You can expect to receive your first container of bottles in 6-7 months after development, provided that the process goes smoothly. This breaks down as follows: Samples usually take 4-6 weeks from the time the mold is ordered. If mold modifications are required, you can expect an extra 2-4 weeks to get new samples each time a change is made, depending on how busy the factory is. Once the sample is approved, it takes 3-4 weeks to complete the full set of production molds. Mass production is currently averaging around 3-4 months. Shipping can take 2-3 months on top of the mass production timing, on average.

What closures are available?

Fusion offers a wide range of closures: metal screw cap (ROPP and stelvin), plastic screw cap, cork (synthetic or natural), etc. We can source just about any kind of closure you might need, and we can offer a range of tamper evidence functionalities.

What is tamper evidence?

There are many methods of providing tamper evidence on bottles. Some closures have breakaway rings on the bottom that come off when you unscrew the cap. Others utilize shrink-wrapped plastic or foil capsules around the bottleneck that must be torn off before the bottle can be opened. Metal twist off lug caps feature a safety button in the center that pops up once the bottle has been opened. Many liquor bottles simply have a piece of paper glued across the closure to the bottle surface that gets torn in the process of opening the bottle.

What sort of labeling and bottle decoration can you do?

Fusion offers two labeling options, including printed labels that are glued to the outside of the bottle, and ceramic heat transfer printing, a method of applying a decal to the bottle that gets baked into the surface of the glass. The cost of the label generally depends on the number of colors and the size of the label. We also offer acid etching, or frosting, for a decorative pattern, or as an overall treatment. Further, we offer custom bottle coloration via food-safe spray coating, a process that bakes externally applied color into the surface of the glass. Alternatively, color may be added directly to the glass material during production, but coloration of this sort only applies in situations involving extremely high quantity production runs.

How are the bottles packed?

Generally, bottles are either packed in reusable cardboard boxes with dividers, or they are packed in bulk on cardboard trays on pallets. Packing in boxes gives added protection to bottles during transit, and is often better for bottles that we ship prelabeled. We can offer varying degrees of cardboard quality and can have the boxes custom printed with a client's corporate or product-specific branding. Customers frequently choose this option, because it allows them to reuse the shipping boxes for the sale of their product. The cost of a box depends on the overall size, the quality of the cardboard, the number of colors required for printing, and the size of the area to be printed. Bulk packing helps bring down the unit shipping cost by allowing a greater number of bottles to be packed in a single container.

Is there breakage during shipment?

Given the inherently fragile nature of glass, there will almost certainly be breakage during transit, but it is usually minimal (losses of less than 1%). Fusion is not responsible for breakage unless it is due to gross negligence on our part.

How do we begin the design process? Do you help with the design process, and do you have a designer on staff?

The best way to begin the design process is to survey the current market offerings to get a feel for the style of bottle that you want. From there, we can provide design assistance and develop drawings and specifications based on your requirements. If you have designs ready, please be sure to supply us with vector art drawings to work from (e.g. AI, DWG, CDR). In conceiving your design, please bear in mind that design elements such as sharp edges, corners and unusual shapes will add significantly to the complexity of the manufacturing process, which will in turn add to the overall production costs.

Can Fusion sterilize the bottles before shipment?

No. Unless they are well sealed, there is no way to guarantee that the bottles would remain sterile during transit. If sterilization is required, it is better to do it near or at the bottling facility, just before filling.

Do the bottles need to be cleaned before filling?

Yes. Although we often pack bottles upside down to reduce the possibility of contaminants getting inside the bottles, we advise that clients clean the bottles prior to filling.

What is hot filling?

Hot filling is a process used to increase the shelf life of a bottled food product. Hot filling at high temperatures can cause the glass to crack or explode due to the temperature variation between the internal and external surfaces of the bottle. Adding extremely hot liquid to a bottle causes the interior surface of the glass to heat up and expand quickly, while the outer surface remains at room temperature and does not expand. The stress that results from the exposure to these extreme temperature differences can cause breakage.

What hot-fill temperature differential can the bottles handle?

When filling the bottles with hot liquid, what is the maximum suggested temperature difference between the bottle and the liquid? 42ºC is usually the maximum we will guarantee. While higher temperature differentials are often manageable, we will not guarantee anything greater. If your particular hot filling process will involve a greater temperature differential, then we suggest that the bottles be preheated so as to avoid the possibility of significant breakage during filling.

What are the copyright or patent laws on reproducing a bottle?

Bottles shapes can be protected with design patents. It is possible to copy a patented bottle and not violate the patent if the shape and size of the bottle are changed slightly from the existing design. Bottles can also be trade-dressed. This is similar to a trademark, and it means that other companies are prohibited from using the same bottle shape and label style for the same product. However, one could sell a different product in the same shape bottle and not violate applicable trade dress. See this article for more info: http://fusion-glassworks.com/img/Trademark_and_Tradedress.pdf.

What is the glass quality of your bottles?

We work with a variety of vendors who proved a range of glass quality options. Average flint glass has a slight grey or greenish tint to it. This is the most common type of translucent glass. Higher quality flint glass has better clarity, but is more expensive as a result. Ultra premium "super flint" has the highest quality and clarity, and is thus the most expensive, but super flint is the standard glass from which bottles for premium spirits, particularly vodka, are made.

Is there lead or any other harmful chemicals in bottles from china?

The glass itself has no lead or other harmful chemicals. Upon request, Fusion can have the bottles tested at an independent test facility to confirm. The ink used for the labels often has lead and/or chromium to increase the vibrancy of the colors. Since the labels are not on a surface that comes in contact with the food product, there are no regulations prohibiting the use of lead or chromium. However, upon request, Fusion can use inks with no lead or chromium

Do you work with green companies?

All of the our vendors use varying levels of recycled glass. The amount used depends on the target glass quality (recycled glass lowers quality) and the requirements of the customer. The highest quality glass will use about 10% recycled material. Lower quality glass has a maximum of about 40% recycled material.

Are bottles from China made in sweatshop factories?

Fusion does not work with any factories that make use of sweatshop or child labor. Fusion's manufacturing partners have been hand picked for an all-around quality manufacturing process - from materials to labor. There are many factories in China with dismal conditions. However, most factories whose products are exported have higher labor standards than factories that only produce for the domestic market. The best way to help bring positive change to Chinese workers is not by refusing to buy Chinese products, but by actively buying Chinese products and using purchasing power to influence labor policy.

Shipping Acronyms:

EXW - Ex Works. This is the cost at the vendor door. No shipping of any kind is included in the price.
FOB - Free On Board cost. This is the cost of the product on a vessel at the FOB location. It means that freight from the vendor to the vendor's port including all export duties and clearance fees have been paid.
CIF - Cost with Insurance and Freight. This is the cost of the product shipped to the CIF port (nearest to the customer) but does not include import duty, customs clearance fees, or domestic shipping to the final location.
DDU - Delivery, Duties Unpaid. This the cost including door to door shipping, but not including import duties or customs clearance fees.
DDP - Delivery, Duties Paid. This the cost of the product door to door including everything.