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Senior Project Presentation
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Senior Project Presentation

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This is a short presentation summarizing a project me and 3 of my peers worked on throughout this past semester in our packaging design and development course.

This is a short presentation summarizing a project me and 3 of my peers worked on throughout this past semester in our packaging design and development course.

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    Senior Project Presentation Senior Project Presentation Presentation Transcript

    • GeradEnterline Kathryn Geiger Tyler Mims Charlie Robnett
    • Sponsor  Project: Patient Clemson’s Architectural and Health Group Prototype Room  Description: Key Contact: David Alison An Interdisciplinary Design- Research Collaboration with the Spartanburg Healthcare System
    • Dispensers  Goals  Help identify/design the optimal package  Considerations  Size  Function  Environmental Impact  Cost
    • Initial Ideas  Flexible Stand-up pouch with nozzle  Flexible Bag with Rigid Corners  Bag in Box  Flexible pouch with puncture head without nozzle
    • Idea Selection  Stand-up pouch  Nozzle  Bottom gusset  Resembles Cassette Volume  Dispensing Method  Storage/Transportation 
    • Steris Product Sanitizer Soap  1 Liter Volume  1 Liter Volume  63% isopropyl alcohol  Contains 0.5% Triclosan  Moisturizes skin  Gentle on skin  Clear and colorless  Off-white in color
    • Material Test  Preferred Material  PET/Adhesive/Nylon- LLDPE Coex  Material Test  Nylon-EVOH Coex  Cast PP
    • Material Results Control Soap Sanitizer Nylon Polypropylene
    • Primary Package Design  Prototype Material  PET/Adhesive/LDPE  1st design  8”x4.5”x3”  0.5 L Volume  2nd design  8”x6”x4”  0.7 L Volume  Final Design  8.5”x6.5”x3.5”  Exceeded 1 L
    • Creating Standup Pouch
    • Geometric and Structural Design 15.92”x 13.32”x 11.64” OD*   Standard RSC  3 x 4 arrangement in case  Corrugate Material: C-flute  Headspace = 0 inches  Required stacking strength of 301 lbs in storage  Required stacking strength of 570 lbs in transport
    • Pallet Pattern Comparison Cassette Pouch •32 boxes per •36 boxes per 13% increase in amount of pallet pallet product •87.5% area used •99.4% area used being •71.1% cube used •98.5% cube used shipped •16128 cassettes •18144 pouches total on load. total on load
    • Distribution Cycle
    • ISTA Procedure 1C Overview Testing Steps  Extended Testing for Atmospheric measurement 1. Packaged-Products 150 lb Compression Conditioning 2. (68kg) or Less Random Vibration 3.  Covers any distribution mode Drop Test 4.  General simulation that will challenge the capability of the package and product to withstand transport hazards
    • Distribution Testing Results After Before
    • Distribution Testing Results PouchFailure during Drop Box Failure during Test Drop Test
    • Distribution Conclusion Problems Next Steps  Need accurate samples  New test needs to be run with accurate prototypes  Nozzles  Test should be a simulation of  Materials actual distribution  Case height reduced to  Case design might work with accommodate samples without nozzles accurate prototypes and simulation test  Not a simulation of actual distribution
    • What if the new test fails? Add strength with a divider Reduce compression and or sleeve drop force 2x4 3x4 with arrangement S divider 2x5 3x4 with arrangement sleeve
    • Machine Capital Investment Close to $750,00 will need to be invested for this machine. Benefits of machine is it will put in the nozzle fitment, fill and seal. Output of 80-480 pouches per minute
    • Machinery Line
    • Machine line efficiency  FORM-FITMENT-FILL, seal 480ppm x .98= 470  Cap Tightening 200ppm x .98 = 196  Coder 1000ppm x .98 = 980  Case erector/ packer 180ppm x .98 = 176  Case sealer 204ppm x .98 = 176  Palletizer 480ppm x .98 = 470  Stretch wrapper 550ppm x .98 = 539  .98 x .98 x .98 x. 98 x. 98 x. 98 x .98 x 180 = 156.26 ppm
    • Financial Assumptions  Volumes  Price per pouch: $0.265  Nozzle cost: $0.50  Soap and sanitizer cost per unit: $0.20  Corrugated Shipper cost: $0.047  Unit sell price: $14.50  Steris’s expected profit margin: 6.1%
    • Financial Projections Year 2009 2010 2011 2012 2013 INCOME Total Volume 0 50,000 100,000 250,000 500,000 Selling Price ($/package) 14.50 14.50 14.50 14.50 14.50 Gross Sales 0 725,000 1,450,000 3,625,000 7,250,000 Net Sales 725,000 1,450,000 3,625,000 7,250,000 EXPENSE Product Cost 0 10000 20000 50000 100000 Nozzle 0 25,000 50,000 125,000 250,000 Pouch 0 13,250 26,500 66,250 132,500 Case 0 196 392 979 1,958 Variable Cost 0 48,446 96,892 242,229 484,458 Plant Fixed Cost Depreciation-Direct 75,000 75,000 75,000 75,000 75,000 Fixed Costs: 75,000 75,000 75,000 75,000 75,000 Gross Margin 0 676,554 1,353,108 3,382,771 6,765,542 Expected Profit 0 44225 88450 221125 442250 Profit per package 0 0.8845 0.8845 0.8845 0.8845
    • Package Transfer  Pros  Cons  Optimized pallet pattern  Recyclability  Decreased package depth  Initial package cost  Less warehousing space  Product waste  Package weight reduction  New capital required  Required landfill space  Low truck clearance reduction  Potential long-term material cost savings
    • Special Thanks  David Allison from  Tom Richard with PPI Clemson’s Architecture Technology and Health Department  Ginger Gregory with  Russell Darley from Regional Hospital Smith & Nephew  Charlie Kilfoyle with  Nancy Jenkins from Steris Curwood a division of  Tom Jennings with The Bemis Village at Pelham  Tara Ford from Amcor  Dr. Darby Flexible Packaging  Dr. Kimmel