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.

1. GeradEnterline
Kathryn Geiger
Tyler Mims
Charlie Robnett

2. 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

3. Dispensers
 Goals
 Help identify/design the
optimal package
 Considerations
 Size
 Function
 Environmental Impact
 Cost

4. Initial Ideas
 Flexible Stand-up pouch
with nozzle
 Flexible Bag with Rigid
Corners
 Bag in Box
 Flexible pouch with
puncture head without
nozzle

5. Idea Selection
 Stand-up pouch
 Nozzle
 Bottom gusset
 Resembles Cassette
Volume

Dispensing Method

Storage/Transportation


6. 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

7. Material Test  Preferred Material
 PET/Adhesive/Nylon-
LLDPE Coex
 Material Test
 Nylon-EVOH Coex
 Cast PP

8. Material Results
Control Soap Sanitizer
Nylon
Polypropylene

9. 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

10. Creating Standup Pouch

11. 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

12. 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

13. Distribution Cycle

14. 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

15. Distribution Testing Results
After
Before

16. Distribution Testing Results
PouchFailure during Drop Box Failure during
Test Drop Test

17. 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

18. 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

19. 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

20. Machinery Line

21. 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

22. 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%

23. 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

24. 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

25. 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