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Marc Brander
 Mike Holzer
Benny Kirchner
  Tyrel Ruch
• Design a unique container for a
new liquid soap product.
• Container needs to hold 28-32
fluid oz. of product.
• Contain...
• Container should be aesthetically
pleasing.
• Container sizing should fit within
the “Golden Section,” or a ratio of
1:1...
• The container must be designed
ergonomically to make it useful to
its purpose. It must fit the hand, and
require only a ...
• Provision must be made for
application of a customer supplied
product label.
• The customer would prefer a
raised surfac...
Per customer request, the original
design specification called for ABS
plastic as the material for this
bottle.
However, research conducted at our
expense has indicated PET
(Polyethylene Terephthalate) would
be better suited for this ...
Reasons for this material change
include:
  • Material Property Advantages
  • Raw Material Cost
  • Recyclability
The material properties of PET
offer a distinct advantage to ABS
for the following reasons:
1. PET can be produced with 99%
   optical clarity, compared to 79%
   with ABS.
2. ABS is a type of styrene known for
   ...
3. Due to its durability and impact
   resistance, ABS provides a stiffer
   wall, causing a need for greater
   force to ...
4. ABS offers a poor surface finish
   and requires secondary coating
   processes to produce a smooth or
   glossy appear...
5. PET will produce clear, glossy
   bottles needing no secondary
   processes.
6. PET is better suited to both
   Extrusi...
PET and ABS are both traded on an
open market. For this reason,
material pricing for both fluctuates
periodically.
Regardless of the fluctuation, virgin
PET pellets (raw material) can be
obtained at a lower cost than ABS.
Prices Listed are Per Pound       Less than 10,000 lbs.          10,000 - 100,000 lbs.                Greater than 100,000...
Re-use and recycling is becoming a
major consideration in corporate
responsibility in the current global
economy.
For this reason, PET is a more
sensible choice ecologically, as it is
more widely accepted in recycling
programs nationwid...
Number 1 Plastics
   PET/PETE (Polyethylene Terephthalate)
   Found in: Soft drink, water and beer
   bottles; mouthwash b...
Recycling: Picked up through most
   curbside recycling programs.

   Recycled into: Polar fleece, fiber,
   tote bags, fu...
PET plastic is the most common for
   bottles because it is inexpensive,
   lightweight and easy to recycle. It
   poses l...
Number 7 Plastics
   Miscellaneous
   Found in: Three- and five-gallon water
   bottles, sunglasses, DVDs, iPod and
   com...
Recycling: Number 7 plastics have
   traditionally not been recycled, though
   some curbside programs now take
   them.

...
ABS plastic, which is classified as a
   Number 7, is one of a wide variety of
   plastic resins that don't fit into any o...
As an incentive, your own scrap PET or
other commercially available recycled
PET may be added to your virgin
material to p...
We considered a number of designs
and styles to satisfy your needs.
The following are a few of our
preliminary design thou...
This diagram
demonstrates the
application of the
“Golden Section” of
1.618:1 in the
bottles dimensions.
All of the
dimensions shown
are related to one
another using this
ratio.
Using a Stratysys Dimension SST
Rapid Prototyping machine, we
were able to create a 1:1 scale 3-
dimensional prototype mod...
The bottle has been ergonomically
designed for easy one handed use.
Using symmetry, the bottle also
 allows for easy left-hand use.
The bottle shape also allows it to be
          stood on its top.
Using a third
interval color
scheme, green, blue
green, and blue
were added to
promote a feeling
of harmony.
Using a third
interval color
scheme, green, blue
green, and blue
were added to
promote a feeling
of harmony.
Using a third
interval color
scheme, green, blue
green, and blue
were added to
promote a feeling
of harmony.
Using a fifth
interval color
scheme, green and
violet were added
to promote a subtle,
yet pleasing
appearance.
Using a fifth
interval color
scheme, green and
violet were added
to promote a subtle,
yet pleasing
appearance.
Using a fifth
interval color
scheme, green and
violet were added
to promote a subtle,
yet pleasing
appearance.
Using a seventh
interval color
scheme, red and
green were used to
promote a feeling
of excitement.
Using a seventh
interval color
scheme, red and
green were used to
promote a feeling
of excitement.
Using a seventh
interval color
scheme, red and
green were used to
promote a feeling
of excitement.
Using COSMOS Works, a Finite
Element Analysis (FEA) software,
we were able to simulate the force
required to squeeze this ...
Our results were as follows:
• Using a squeezing
                            force of only four
                            pounds, the bottle
        ...
• We feel that four
                       pounds of force is
                       a very reasonable
                   ...
• and that this
                             amount of
                             deformation should
                   ...
Initial Volume                            63.39                                    Cubic Inches
 (-) Final Volume         ...
We designed this bottle to feature
an inverted style cap. This style has
gained popularity on a wide variety
of products, ...
We have sourced a cap for this
bottle from Zeller Plastics, and the
cap is available through McKernan
Packaging.
The neck is produced using the PBI
L28SP400 finish, and a number of
manufacturers offer similar caps in
this size.
This cap, P/N 3812-28400, is
available at a cost of $0.57 each in
quantities of 1000.
The cap shown here features a one
way silicone valve to prevent drips
and to limit flow.
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
Plastic Bottle Design
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Plastic Bottle Design

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This is an example of a team design scenario. The scenario involve designing a container for the Colgate-Palmolive Company to hold 28-32 oz. of a new product. The original specification called out for the use of ABS plastic in its construction, but in our research we determined that PE was a more suitable choice.

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Plastic Bottle Design

  1. 1. Marc Brander Mike Holzer Benny Kirchner Tyrel Ruch
  2. 2. • Design a unique container for a new liquid soap product. • Container needs to hold 28-32 fluid oz. of product. • Container must have a method for seeing remaining product.
  3. 3. • Container should be aesthetically pleasing. • Container sizing should fit within the “Golden Section,” or a ratio of 1:1.618 width to height.
  4. 4. • The container must be designed ergonomically to make it useful to its purpose. It must fit the hand, and require only a reasonable amount of force to dispense the product.
  5. 5. • Provision must be made for application of a customer supplied product label. • The customer would prefer a raised surface on which to affix their label.
  6. 6. Per customer request, the original design specification called for ABS plastic as the material for this bottle.
  7. 7. However, research conducted at our expense has indicated PET (Polyethylene Terephthalate) would be better suited for this product.
  8. 8. Reasons for this material change include: • Material Property Advantages • Raw Material Cost • Recyclability
  9. 9. The material properties of PET offer a distinct advantage to ABS for the following reasons:
  10. 10. 1. PET can be produced with 99% optical clarity, compared to 79% with ABS. 2. ABS is a type of styrene known for its durability and impact resistance.
  11. 11. 3. Due to its durability and impact resistance, ABS provides a stiffer wall, causing a need for greater force to be exerted in this squeeze bottle application.
  12. 12. 4. ABS offers a poor surface finish and requires secondary coating processes to produce a smooth or glossy appearance.
  13. 13. 5. PET will produce clear, glossy bottles needing no secondary processes. 6. PET is better suited to both Extrusion Blow Molding and Stretch Blow Molding.
  14. 14. PET and ABS are both traded on an open market. For this reason, material pricing for both fluctuates periodically.
  15. 15. Regardless of the fluctuation, virgin PET pellets (raw material) can be obtained at a lower cost than ABS.
  16. 16. Prices Listed are Per Pound Less than 10,000 lbs. 10,000 - 100,000 lbs. Greater than 100,000 lbs Generic High Low Avg. High Low Avg. High Low Avg. ABS $2.42 $0.83 $1.43 $1.25 $0.66 $0.96 $1.15 $0.68 $0.91 ABS (30% glass) $1.25 $1.25 $1.25 ABS - Medium Impact $0.89 $0.85 $0.87 ABS - High Impact $0.86 $0.86 $0.86 $1.24 $1.24 $1.24 Polcarbonate + ABS $4.25 $3.93 $4.09 $2.60 $0.90 $1.75 Polycarbonate + PET (Imp. Mod) $2.87 $2.87 $2.87 HDPE $0.82 $0.57 $0.67 $0.89 $0.49 $0.72 $0.79 $0.53 $0.64 HDPE (widespec, virgin) $0.42 $0.42 $0.42 HDPE (co-pp) $0.36 $0.36 $0.36 LDPE $0.94 $0.94 $0.94 $0.80 $0.72 $0.76 LLDPE $3.30 $1.40 $2.35 $0.93 $0.93 $0.93 $0.85 $0.50 $0.70 PET $1.50 $1.28 $1.43 $0.67 $0.67 $0.67 $0.70 $0.45 $0.56 Source: IDES Plastics quot;The Plastics Web.quot; Retrieved 2008-10-23, from http://www.ides.com/resinprice/resinpricingreport.asp
  17. 17. Re-use and recycling is becoming a major consideration in corporate responsibility in the current global economy.
  18. 18. For this reason, PET is a more sensible choice ecologically, as it is more widely accepted in recycling programs nationwide.
  19. 19. Number 1 Plastics PET/PETE (Polyethylene Terephthalate) Found in: Soft drink, water and beer bottles; mouthwash bottles; soap bottles; peanut butter containers; salad dressing and vegetable oil containers. Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
  20. 20. Recycling: Picked up through most curbside recycling programs. Recycled into: Polar fleece, fiber, tote bags, furniture, carpet, paneling, straps, (occasionally) new containers. Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
  21. 21. PET plastic is the most common for bottles because it is inexpensive, lightweight and easy to recycle. It poses low risk of leaching breakdown products. Recycling rates remain relatively low (around 20%), though the material is in high demand by remanufacturers. Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
  22. 22. Number 7 Plastics Miscellaneous Found in: Three- and five-gallon water bottles, sunglasses, DVDs, iPod and computer cases, signs and displays, certain food containers, nylon Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
  23. 23. Recycling: Number 7 plastics have traditionally not been recycled, though some curbside programs now take them. Recycled into: Plastic lumber, custom- made products Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
  24. 24. ABS plastic, which is classified as a Number 7, is one of a wide variety of plastic resins that don't fit into any of the other categories. Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321
  25. 25. As an incentive, your own scrap PET or other commercially available recycled PET may be added to your virgin material to produce a cost savings.
  26. 26. We considered a number of designs and styles to satisfy your needs. The following are a few of our preliminary design thoughts:
  27. 27. This diagram demonstrates the application of the “Golden Section” of 1.618:1 in the bottles dimensions.
  28. 28. All of the dimensions shown are related to one another using this ratio.
  29. 29. Using a Stratysys Dimension SST Rapid Prototyping machine, we were able to create a 1:1 scale 3- dimensional prototype model of our design proposal.
  30. 30. The bottle has been ergonomically designed for easy one handed use.
  31. 31. Using symmetry, the bottle also allows for easy left-hand use.
  32. 32. The bottle shape also allows it to be stood on its top.
  33. 33. Using a third interval color scheme, green, blue green, and blue were added to promote a feeling of harmony.
  34. 34. Using a third interval color scheme, green, blue green, and blue were added to promote a feeling of harmony.
  35. 35. Using a third interval color scheme, green, blue green, and blue were added to promote a feeling of harmony.
  36. 36. Using a fifth interval color scheme, green and violet were added to promote a subtle, yet pleasing appearance.
  37. 37. Using a fifth interval color scheme, green and violet were added to promote a subtle, yet pleasing appearance.
  38. 38. Using a fifth interval color scheme, green and violet were added to promote a subtle, yet pleasing appearance.
  39. 39. Using a seventh interval color scheme, red and green were used to promote a feeling of excitement.
  40. 40. Using a seventh interval color scheme, red and green were used to promote a feeling of excitement.
  41. 41. Using a seventh interval color scheme, red and green were used to promote a feeling of excitement.
  42. 42. Using COSMOS Works, a Finite Element Analysis (FEA) software, we were able to simulate the force required to squeeze this bottle to dispense the product within.
  43. 43. Our results were as follows:
  44. 44. • Using a squeezing force of only four pounds, the bottle will deform .330 inches per side. COSMOS – von MISES STRESS
  45. 45. • We feel that four pounds of force is a very reasonable amount of force to exert; COSMOS – DEFORMATION
  46. 46. • and that this amount of deformation should provide sufficient internal pressure to dispense the product. COSMOS – EQUIVALENT STRAIN
  47. 47. Initial Volume 63.39 Cubic Inches (-) Final Volume 3.99 Cubic Inches 59.40 Cubic Inches Conversion Factor 0.5541125541 32.91 Fluid Ounces Source: Online Conversion.com http://www.onlineconversion.com/volume.htm, based on the formula 1 cubic inch = 0.554 112 554 1 ounce [US, liquid]
  48. 48. We designed this bottle to feature an inverted style cap. This style has gained popularity on a wide variety of products, and we feel that it is ideal for this application.
  49. 49. We have sourced a cap for this bottle from Zeller Plastics, and the cap is available through McKernan Packaging.
  50. 50. The neck is produced using the PBI L28SP400 finish, and a number of manufacturers offer similar caps in this size.
  51. 51. This cap, P/N 3812-28400, is available at a cost of $0.57 each in quantities of 1000.
  52. 52. The cap shown here features a one way silicone valve to prevent drips and to limit flow.

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