Hey crew, need some help from packaging people.
We've got a new HDPE molder that makes 28mm closures (no liner) for us with a tamper band. My concern with it however is that we have no 100% inspection device on these caps to ensure they mold and cut correctly. In the past we've received bad caps from suppliers where tamper bands either break on application, or they don't break and the bottles become difficult to open, and customers see it as a serious quality defect when the tamper band doesn't hold before opening and break properly during opening.
Does anyone have experience working with a cap forming machine like this? What sort of quality check interval/SPC numbers did you work with? How do you verify that the machine is producing perfect caps 99.99% of the time when you don't have a 100% inspection device?