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MS&E 264 - Sustainable Product Development
Final Project Report
Team Wrigley
November 28, 2010
Team Members: Kyla Barr, Aleema Jamal, Abigail Soong, Lily Truong

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Table of Contents
Section Page Number
1) Project Report
a. Executive Summary ……………………………………………………….....3
b. Principle Objectives………………………………………………………..…3
c. Market and Customer Need Analysis ……………………………………..…3
d. Product Design Description and Operating Features……………………..…..4
e. Product Performance & Sustainability Requirements &
Competitive Differentiators ……………………………………………………...5
f. Technical & Commerical Feasibility of the Product………………………....5
g. Product Development Plan……………………………………………….…...8
h. Challenges, Risks, and Opportunities …………………………………….….9
i. Ethical Considerations …………………………………………………..…..10
2) Appendix A – Research Brief………………………………………………………..11
3) Appendix B – Benchmarking and Current Gum Packaging………………………....14
4) Appendix C – Product Prototyping and User Feedback …………………………….15
5) Appendix D – Final Recommendations and Product Design………………………..18
6) Appendix E – Material and Manufacturing Feasibility Analysis……………………19
7) Appendix F – Final Prototype Images ………………………………………………23

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Executive Summary: This project is a combination of the field study and new product
development projects. It builds upon the user and prototype research that was conducted for
Wrigley China to design gum packaging for their “Extra brand”, geared toward the Chinese
market. In conjunction with the development of the final packaging recommendation, we
researched and identified the principle recommended sustainable manufacturing requirements
(using Polylactic Acid [PLA] bioplastic for the already-established injection molding process).
As a result, this process yields the largest benefits for Wrigley as it utilizes already existing
infrastructure to pioneer sustainable product development across the industry in China at a
decrease in cost for raw-material to Wrigley.
Principle Objectives: The principle objectives for the project were to develop a sustainable gum
package at minimal additional cost to Wrigley, which would conform to the user needs and
values identified during the user research and market analysis in China. While Wrigley’s product
differentiation comes from the packaging design, its primary goal in adding sustainability into
their product framework is be an industry leader as China is pushed towards increasing
government regulation.
Market and Customer Need Analysis: The market research provided by Wrigley, China, in
combination with a variety of deep-dive interviews and broader user surveys, were conducted to
determine the target market and user needs for this new Extra brand of gum packaging. Wrigley
defined our target market as female, ages 24-35, who are health and oral care conscious, and
driven toward personal lifestyle improvement and general success1
. Our further research
complemented the demographic as being students and young professionals who are health and
image conscious, and driven toward professional success and social acceptance.
1
Initial Market Research and Project Brief Provided by Wrigley. January 2010 (available upon request)

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With this re-defined user group, we were able to further target our deep-dive interviews
to identify key values. The ethnographic research we conducted in China yielded the following
results regarding Chinese perceptions of health, the importance of social interactions and
relationships, the importance of cleanliness, and the value found in stories and history. While the
full results of our research can be found in the research brief previously submitted to Wrigley,
and attached as Appendix A, below is a brief summary:
Perceptions of Health: Health is very important for the Chinese way of life and has deep roots in
Traditional Chinese Medicine through practices such as ‘Kao Chi’. For younger individuals, main health
concerns include stress management, retention of focus, and the aesthetic of the mouth. Fresh breath and
clean teeth are important
Importance of Social Interactions and Relationships: Gum provides the opportunity to “break the ice”
when establishing new relationships, in combination with its function as an item to share with friends
(thus acting as a sign of respect). Gum is also viewed as an important means to freshening breath.
Importance of Cleanliness: Cleanliness has significant importance for both gum and gum packaging.
Gum pellets should not be exposed to unclean materials or the bare skin.
Stories and History: The Chinese consumer places much value on stories and history when deciding to
buy a product, especially one which will enter the household. Furthermore, yellow teeth are reminiscent
of women in the cultural revolution and thus, the value of oral health can be found within historical
contexts (highlighted in anecdote 7 of the research brief).
Given the above user values, four core user needs were developed and utilized as the
guiding force for the design of the new gum packaging: 1) Noise Reduction, 2) Portability and
function, 3) Hygienic and controlled dispensing, and 4) Easy and Clean disposal. Although
sustainability was not explicitly a need identified during the user research, it was one identified
by Wrigley as a company milestone, with the hope of pioneering the slowly changing industry
trend toward increased environmental standards.
Product Design Description and Operating Features: With the previous information in mind, and
after multiple iterations of brainstorming, benchmarking, prototyping, and user feedback
(highlighted in Appendix C), the product design recommended and supported by Wrigley China
possessed the following features: 1) A slim form factor for mobility and easy pocket storage, 2)

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easy controlled dispensing mouth on the side of the container, 3) sound reduction through low
profile, 4) a tissue compartment that has an environmental shield (keeping disposal paper clean),
and an innovative graphic design which identifies with the user and promotes the oral care brand.
In addition, the product may feature a refillable door for reusable packaging, which can therefore
act as a complement to current Wrigley products and further their desire to attain environmental
sustainability. The tissue disposal papers will also be printed with graphics, oral hygiene facts,
and environmental sustainability facts to promote education and sharing. A graphical
representation of the final recommendation is located in Appendix D.
Product Performance and Sustainability Requirements and Competitive Differentiators:
The current gum packaging in China (across the principle competitors) takes the form of “pill
bottle” like dispensers (Appendix B). This often bulky package poses challenges for user
portability, consumption, and disposal, but has not been changed in light of the lack of variation
among competitors. Given Wrigley’s desire for innovation and recognition of unmet consumer
needs (highlighted above), the new gum packaging has been designed to pave the way for a new
innovative health and sustainability driven mindset in China. Full graphics are included in
Appendices D and F, and a complete product feasibility analysis has been conducted below.
Technical & Commercial Feasibility of the Product: This commercialization of this new gum
packaging in China would require initial (but manageable) infrastructure investments: namely
the monetary contribution required to re-tool any additional molds, while generating any new
manufacturing lines within the current factory. Since this new product is designed with the
objective of replacing a significant portion of the current Extra “bottle” sales, it is predicted that
economies of scale would be significant enough to justify any new infrastructure developments.

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Although the development of new manufacturing moulds would be required to develop
the new gum packaging, the basic technology would remain the same, namely the use of
injection molding. As a direct result, the only additional costs for the implementation of this new
gum package would be the raw-material costs resulting from the purchase of sustainable and
compostable materials.
A variety of environmentally sustainable materials and processes were assessed for
economic, environmental, and political feasibility. The full feasibility analysis for these products
is included in Appendix E. PLA was chosen because it is considered as the bioplastic with the
“most promise”. Currently, 10 billion pounds of plastic are made per year in comparison with the
0.3 billion pounds of bioplastics made globally per year2
. As a result, the reach of bioplastics
within industry is growing at a significant rate, indicating that Wrigley’s opportunities to use
such materials are growing and becoming more economically feasible. Currently, PLA has the
highest production capacity and is the most established leader in the bioplastics industry.3
As a
result, it is one of the only feasible options for sustainable materials (that also satisfies our other
user-requirements).
PLA was also selected because it uses all the same tooling as the normal high density
polyethelene (HDPE), which is the material Wrigley currently uses for the production of its
bottle-based gum packaging. As a result, a switch to PLA will not require a change in the
manufacturing process. Furthermore, PLA’s aesthetic benefits conform perfectly to the already
established user needs and values.
2
The Properties of Polylactic Acid. http://www.matbase.com/material/polymers/agrobased/polylactic-acid-
pla/properties. Online, Available. November 28, 2010
3
Properties of HDPE. Online, Available. November 29, 2010
http://www.matbase.com/material/polymers/commodity/hdpe/properties

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Firstly, PLA has a higher tensile strength than the currently used HDPE, at 60MPa versus
32MPa. Tensile strength – defined as the maximum stress a material can take before failure –
indicates that PLA is a highly durable material, and will not crush through daily use and
weathering (a need which was clearly vocalized through prototype user feedback). As a direct
result of PLA’s higher density and durability, the thickness of the material used for the product
can be reduced to 40 thousandths of an inch, half the thickness currently used in the normal gum
packaging. This thickness reduction decreases the volume of materials by half, and therefore, the
mass of material by half as well. The amount of resin needed per case is therefore reduced by
33.6%, which leads to an overall reduction in cost by 50% (or 1 cent per case) in comparison
with the current bottle (refer to Appendix E for full production benefits of PLA and full
calculations).
PLA has been declared as “food safe” by the FDA, a particularly important factor to
consider given the implications for Wrigley with regard to the nature of the products it packages.
Finally, the PLA material is commercially available in resin pellets (which possess the property
of being opaque), thereby eliminating the necessary resources and time required to inject
biodegradable dyes as a separate part of the manufacturing process. The opaque quality of the
material was particularly important for Chinese users due to its aesthetic implications.
Environmentally, the use of PLA decreases fossil fuel use from the current process by
37.5% (which includes the fossil fuels used for the energy of production, and inputted into
materials). The production and transportation of PLA also decreases the greenhouse gas
emissions by 62% (refer to Appendix E), therefore posing significant implications for China
regarding its greenhouse gas emissions targets, particularly if Wrigley’s standard becomes an
industry-wide standard.

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Given the above analyses, it is evident that the use of PLA will enable Wrigley to meet its
environmental and sustainability targets without the risk of incurring significant additional costs
for the company.
**Note: In the interest of space, a more detailed materials and manufacturing process analysis is
included in Appendix E.
Product Development Plan: In addition to any infrastructure and manufacturing changes that are
necessary to commercialize the product (prototypes and user feedback have already been
generated), Wrigley will have to take the following steps to ensure successful implementation: 1)
An aggressive marketing strategy focusing on the user-generated benefits from utilization of the
gum package, in combination with its posed oral health and environmental benefits, 2) continued
gathering of user feedback and product change recommendations in 1-month, 6-month, and
yearly cycles after the initial product launch, and 3) continued sustainability and competitive
analysis to determine potential competitive responses, and Wrigley’s continued sustainability
approach and expansion to its other product lines.
We recommend that Wrigley commences with a test launch of its product in tier A cities
(Beijing, Shanghai, etc…), to garner user feedback and initial market data (as per the above
plan), before launching nation-wide. In this way, the risks associated with product launch will be
minimized.
Challenges, Risks, and Opportunities: Although there exists an inherent risk with the launch of
any new product into the marketplace, Wrigley’s primary concern is the implications of its
sustainability measures. China, in light of its heavy consumption and dense population, is facing
increasing international pressure to become more sustainable in its energy and industrial
processes. Wrigley would be paving the way as one of China’s first large-scale multinational

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corporations to institute sustainability contingencies in its product manufacturing. If Wrigley
were to convert all its products to compostable bioplastics, environmental benefits would come
through the elimination of toxins associated with production, and increased media coverage and
competitive response. However, it is evident that China does not currently possess the
widespread infrastructure to recycle and compost generic products. This leads to concerns
regarding the efficacy of developing such a product without the national infrastructure to support
it.
Wrigley, however, is in the position to capitalize on this national shortcoming by
developing the initial facilities (in major cities) for example, to fulfill the most basic needs. In
this way, Wrigley will not only set the industry standard, but drive the country’s environmental
processes, thereby presenting immense benefits through media, user-value creation, and
possibilities for future government contracts, in combination with the low costs of conversion
resulting from its leadership position, as opposed to its competitors (who may experience
increased costs of conversion in the future).
At the same time, it will be challenging to create a consumer culture and infrastructure
centered on environmentalism and sustainability, even though the cultural roots for this type of
consumption already exist within China. Wrigley will therefore have to be very strategic in its
approach to sustainability implementation in China, ensuring that it receives more than
proportional benefits for any additional costs incurred.
Ethical Considerations Significant debate rests around the use of plastics made out of food-based
products (particularly corn-starch). With food shortages in the developing world comprising
some of the most significant developmental challenges, it is questionable as to whether using
food products to produce consumer goods rather than feed some of the most impoverished

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populations, is the ethical course of action. Research has been completed demonstrating the
implications of corn use in biofuels, both of which have driven up world food prices (due to
decreased supply)4
.
On the other hand, literature expresses that the problem does not lie in diminished food
quantities, but rather in food distribution5
, in which case Wrigley would not have to consider the
implications of using bioplastics for its new generation of gum packaging. In either case,
Wrigley is filling an ethical imperative by being environmentally conscious in its production,
thereby indicating that this argument should not be its primary consideration.
Overall, the use of bioplastics in the creation of Wrigley’s new Extra packaging will position the
corporation to achieve its objectives with significant future benefits.
4
The Ethics of Biofuels. http://www.energybulletin.net/node/24169. Online, Available November 28, 2010
5
Messer, Ellen and De Rose, Laurie F. Food Shortages. Online, Available. November 28, 2010
http://unu.edu/unupress/unupbooks/uu22we/uu22we09.htm

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Appendix A
Market Research and User Needs
Prepared by Original Team Wrigley, Spring 2010
Beijing, China
Research Brief
The following is a brief analysis of the data we completed, with valuable anecdotes that have
helped us determine our focus areas for the brainstorm process. All interview notes, videos, and
recordings are available upon request.
Interviewee Profiles
Age Male Female Total
20-30 5 (PKU + CAFA) 4 (PKU, CAFA,
Dental Clinic)
9
30-50 1 (CAFA Marketing
Professor)
2 (Personal Home) 3
50+ 0 2 (Home, Dentist) 2
Total 6 8 14
Identified Needs for Gum Packaging # of Repetitions Among Respondents
Portability 3
Dispense 3
Disposal 2
Noise 3
Recognized Reasons for Chewing Gum # of Repetitions Among Respondents
Entertainment (boredom) 3
Fresh Breath 5
Sharing and Friendship 2
Substitute for Food 1
Stress Alleviation 3
Tool to Aid with Focus 2
Important Considerations when
Chewing Gum
# of Repetitions Among Respondents
Price is important 4
Sacrifice for Convenience 1
Cleanliness 3
Importance of Oral/General Health 1
Oral/General Health not Important 2
Flavor Important 3
Flavor not Important 1
Oral Appearance important
-white teeth
-healthy gums and tongue
4

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Although the previous numbers give insight into the frequency of mentioned factors within the
realms of gum packaging, fulfilled needs, and considerations, the most powerful data comes
through the stories shared within our deep dive interviews (as this is how majority of our data
collection was structured).
Anecdotes:
Anecdote #1: Gum is often considered in the context of social interactions. One interviewee
emphasized that sharing gum is a sign of “respect” among friends, while another indicated that
gum provides an opportunity to break the ice and establish new social relationships.
Anecdote #2: Gum has been utilized most frequently as a tool to control stress and enable focus.
Having “another part of the body moving”, especially during the act of studying, positively
impacts focus and concentration. For one individual, gum is necessary when playing sports. This
individual “feels like [he] could play in the NBA when chewing gum” as it increases feelings of
strength, concentration, and connection with the ball.
Anecdote #3: One individual chooses flavors of gum (regardless of brand), based on her mood,
and current activity. Although gum packaging will encourage her to try new flavors and brands,
in the end, she will always differ back to the gum of superior quality.
Anecdote #4: Cleanliness (or lack thereof), has dissuaded individuals from using certain
packages if gum is dispensed in large quantities, and therefore touches the hand in the process of
sharing before entering the oral cavity. Similarly, an inability to hygienically dispose of chewed
gum has been recognized as a hindrance. One interviewee inquired as to the “expiry date” of
gum when offered.
Anecdote #5: One interviewee indicated that she transferred gum pellets from the store-bought
gum package to a more “stylish box” sitting on her desk, highlighting the aesthetic value of
permanent objects in a space.
Anecdote #6: Interviewees understood oral health to be directly linked to the aesthetic of the
mouth. In Traditional Chinese Medicine, good oral health is an indicator of general body health,
and includes white and well-aligned teeth, and a health appearance in lips, gums, and on the
tongue. Oral health benefits to gum were mentioned in relation to Kao Chi, the traditional
practice of “gnawing” the teeth together to build strong muscles. Gum was also used by some
interviewees as a substitute for brushing when it became too painful.
Anecdote #7: One interviewee was born at the end of the Cultural Revolution, during which
prescribed antibiotics (for illness), stained her teeth yellow and brown. She has since been
particularly conscious of her oral health, and that of her children, and has used gum as an oral
health tool. She cites this particular challenge as one which pertains to an entire generation.
Anecdote #8: Gum was recognized as providing a feeling of “achievement and satisfaction”
because it lasts for a long time, as opposed to candy, which disappears quickly.

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Anecdote #9: One interviewee chews both Extra and Doublemint. She equates each brand as
follows:
She is also a firm believer in the Extra brand and its marketing, and believes that Extra will
protect oral health.
Anecdote #10: Our dentist interview suggested that most patients come to the dentist because
their teeth hurt, rather than in an effort to complete preventative treatment (like teeth cleaning).
She also indicated that most Chinese are indifferent towards oral health, and to them, any
concept of oral health means “no hurting”.
Anecdote #11: One interviewee mentioned that chewing gum for her children became a traveling
tradition (to help pop ears and provide a distraction in the airplane). While she tries not to
provide too much gum for her children, they are influenced by the example of other children at
school. She does not purposefully buy gum, but rather does so as an afterthought at the cashier
after grocery shopping.
Anecdote #12: The marketing professor at CAFA offered insights in packaging that include the
following:
a) A public preference towards bright colors and packages (no dark colors like brown,
blue, purple, etc…)
b) Images and drawings of nature, landscapes, and trees signify health, “freshness”, etc..
c) It is rare to see different and unique packaging shapes, but they would be valuable to
leverage for “eye-catching appeal”. Simplicity is favored.
d) The Chinese market is more picky than the American market, with purchasing
decisions based on the “story” behind the product, rather than the product itself
Conclusions:
While the previous brief provides only an overview of some of our findings, we have dissected
our results to identify four specific areas to address with regard to gum packaging as follows:
1) Noise
2) Size and Portability
3) Dispensing of Gum
4) Disposal of Gum
These will be our key focus areas throughout the brainstorm and prototyping process, with the
intent of keeping in mind key needs, values and considerations such as oral health, social
networking, and general public perceptions.
Extra = Xylitol
Doublemint = Candy = Gum

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Appendix B
Current Gum Packaging Best Practices
Current gum packaging in China (from a variety of corporations including Wrigley and its chief
competitor Lotte), is bulky, difficult to carry, and presents challenges for the dispensing and
disposal of gum. Examples can be seen below.

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Appendix C
Product Prototyping and User Feedback
Our principle ideas, prototypes and user feedback for each round of prototyping are available
upon request (examples are illustrated on the following page). A distinct focus was selected for
each round of prototyping. While round 1 of the prototyping process focused on the core values
established above, round 2 expanded on these core values by taking on the focus of packaging
geared toward personal use versus sharing. Below are the key lessons from each round of
prototyping:
Prototype Round Focus Principle Lessons
Initial Concepts
Round 1
Quiet Packaging
Portability and Function
Dispensing
Disposal
-Disposal paper: cleanliness
and texture are key
considerations
-Economical material usage
and design
-Package should be portable
and aesthetically pleasing
through the use of
innovative shapes,
symmetry and curved edges
-Rigid packaging is seen as
more durable and luxury
centered
Revised Concepts
Round 2
Packaging for Personal Use
Packaging Aimed at Sharing
-translucent or transparent
packaging is undesirable
-Thin packages, easily able
to fit in the pocket are the
most valuable
-Difficult dispensing from
top opening
-One handed actuation is
desirable
Final Concepts
Round 3
See conclusions and
recommendations
No fieldwork conducted

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Previously Conceived Designs and Feedback
Prototype # 1 Feedback:
a) Paper can be lost in the container
b) The medium height does not reduce
noise
c) The paper does reduce sound
d) Container should contain more
pellets
Prototype # 2 Feedback:
a) Cool and unique shape
b) Need for higher quality material
c) Avoid sharp points
d) Should have disposal built in
e) Refilling is important
Prototype # 3 Feedback:
a) No disposal here
b) Pen shape is convenient

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Prototype # 4 Feedback:
a) Concerns about the outside paper
becoming dirty
b) Did not like paper that touched the gum
c) Paper was too thin
Prototype # 5 Feedback:
a) Bottle should be shorter
b) Translucent bottle is better than
transparent
c) Paper is not seen as clean as it is quite
exposed

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Appendix D
Final Recommendations to Wrigley
Based on our research and prototype testing throughout the past six months, our final solutions
bridge our core values, taking into account the degree of user satisfaction and value placement.
Our final prototype and recommendation therefore has the following qualities:
1. A slim form factor for mobility and easy pocket storage
2. Easy controlled dispensing mouth on the side of the container
3. Sound reduction through low profile
4. A tissue compartment that has an environmental shield (keeping disposal paper clean)
5. Innovative graphic design which identifies with the user and promotes the oral care brand
Optional:
* Refillable door for reusable packaging, which can therefore act as a complement to current
Wrigley products.
* Tissues with printed graphics and oral hygiene facts to promote education and sharing
Disposal Paper:
With oral hygiene facts
Environmental
disposal paper
shield
Small side opening
for one pellet release
Slim form factor for
portability

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Appendix E
Material Feasibility Analysis
Manufacturing Process Analysis
Technical Feasibility
Manufacturability:
The product can indeed be easily manufactured. Our research had found that both PLA and PHB
material can be easily translated to many machining processes used on common petro-based plastics.
For this particular product, injection molding will be utilized.
Injection molding is a process in which pellets of a thermoplastic are heated and forced into an
aluminum mold cavity. The plastic is allowed to cool and hardens in the configuration of the given
shape. A schematic can be seen be seen below:
Injection molding schematic (http://www.plasticinjectionmolds.org/plastic-injection-molding/)
There are many advantages to using injection molding:
• cheap cost of labor
• minimal finishing required
• minimal scrap loss
• raw material can be reused
• high production rate
One design constraint , which affects the manufacturing and sustainability of our product, is the
need for an opaque container rather than a transparent one. Both PLA and PHB are transparent,
however companies are beginning to research and create biodegradable alternatives. Two years ago,
a plant-based yellow colorant called curcumin was found to have the appropriate colorfastness and
mechanical strength properties to be compatible with common biodegradable plastics. Teknor Color
announced this past June the launch of itsbio-based color concentrates for use with PLA and PHB.
Environmental Impact:
The material of the product will either be PLA or PHB. Both PLA and PHB are typically created
with cornstarch or from sugar cane, however, can also be produced using other renewable matter.

20. - 20 -
Although they are both transparent when synthesized, an eco-friendly dye can be used to make the
plastics opaque (as preferred by the target users). These two bioplastics have a zero net carbon
footprint and can be safely composted after use. Therefore, it is feasible to make a sustainable
product.
Commercial Feasibility
Market Adoption:
The market is likely to adopt the product because the look and feel of the design meets the user
needs, which were determined by extensive ethnographic and user research.
Design Meets User Needs:
• Noise Reduction
o low profile reduces rattling of gum pieces
• Hygienic and Controlled Dispensing
o single pellet dispenser without requiring physical interaction
• Easy and Clean Disposal
o contains area for dispense papers
o only single sheet is exposed each time
• Portability
o thin/sleek design allows to fit in pocket or small purse
• Aesthetics
o Opaque
Cost:
Based on the cost estimate of $1.36 per part, the commercial feasibility of being able to manufacture
the product at high volume and at reasonable cost is very high. It is also worth noting that given that
the containers will be manufactured in china initially, the given estimates represent an upper limit of
the costs since manufacturing in china is cheaper. As volume of production increases, prices will
continue to decrease.
The cost of material and manufacture of the product from low quantities to high quantities are
shown in the table below:
*Cost
Estimates were based off of prices at Protomold, an injection molding manufacturer in the U.S.; also
the estimate is based on the assumption that the cost of PLA and PHB are comparable to traditional
injection molding resins such as ABS.
Distribution Channel:
Wrigley already has distribution channels in place for its other products in China. Therefore, the
product can easily be entered into the Wrigley’s existing distribution channels to reach its users.
Injection Molding Cost Estimate*
Initial Prototypes Commercialization
Quantity 10 100,000
Tooling Cost $2645 $500
Price/part $2.21 $1.36
Total $2700.25 $136,500

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Materials Research and Manufacturing Process
Comparison of PLA with Currently Used HDPE
Characteristic Units HDPE PLA % Change from
HDPE to PLA
Performance
Tensile Strength MPa 32MPaa 60MPab N/A
Opaque N/A YES YES N/A
Environmental Impact
Resin Needed per
Case1
g/case 11.6 7.7 -33.6
Greenhouse Gas
Emissions2
Lbs of CO2
equivalent
per case
0.054 0.020 -62.0
Fossil Resource3
Lbs of FRU
per case
0.024 0.015 -37.5
Cost
Resin Cost4
Dollars/case $0.02 $0.01 -50.0
Manufacturing Cost5
Dollars/case $0.05 $0.05 0.0
Volume of Case
!
V = thickness" surfacearea
Volume of HDPE case=
!
0.040in "18.75in2
"
2.543
cm3
in3
=12.3cm3
Volume of PLA case=
!
0.020in "18.75in2
"
2.543
cm3
in3
= 6.15cm3
Note: Because the density and tensile strength of PLA is higher, the case’s thickness can be
reduced by half compared to the HDPE case.
1
Resin Needed Per Case
Grams per case=Volume x Density
Grams of HDPE per case=
!
12.3cm3
case
"
0.941g
cm3
=11.6g/case
Grams of PLA per case=
!
12.3cm3
case
"
0.941g
cm3
= 7.7g/case
2
Greenhouse Gas Emissions
Lbs of CO2 equivalent per HDPE
case=
!
2.10lbs of Co2 equivalentc
lb of resin
"
1lb
453.59g
"
11.6g
case
= 0.054lbs of Co2 equivalent per case

22. - 22 -
Lbs of CO2 equivalent per PLA
case=
!
1.20lbs of Co2 equivalentc
lb of resin
"
1lb
453.59g
"
7.7g
case
= 0.020lbs of Co2 equivalent per case
% Change from HDPE to PLA=
!
0.020 " 0.054
0.054
#100 = "62.0%
3
Fossil Resource
Lbs of FRU per HDPE case=
!
0.94lbs of FRUc
lb of HDPE
"
1lb
453.59g
"
11.6g
case
= 0.024lbs of FRU per case
Lbs of FRU per PLA case=
!
0.86lbs of FRUc
lb of HDPE
"
1lb
453.59g
"
7.7g
case
= 0.015lbs of FRU per case
% Change from HDPE to PLA=
!
0.015 " 0.024
0.024
#100 = "37.5%
4
Resin Cost
Resin Cost per HDPE case=
!
$0.59c
lb
"
1lb
453.59g
"
11.6g
case
= $0.02 case
Resin Cost per PLA case=
!
$0.75c
lb
"
1lb
453.59g
"
7.7g
case
= $0.01case
% Change from HDPE to PLA=
!
0.01" 0.02
0.02
#100 = "50.0%
5
Reference: http://www.alibaba.com/product-
gs/218630865/chewing_gum_bottle_40ml_to_200ml.html
Manufacturer: Zhongyi Packaging Packing Co.,Ltd Fujian
Manufacturing cost per case: $0.05
Note: Because switching from HDPE to PLA does not require any change in the injection
molding manufacturing process, the cost of manufacturing does not change.
% Change from HDPE to PLA=0.0%
a http://www.matbase.com/material/polymers/agrobased/polylactic-acid-pla/properties
b http://www.matbase.com/material/polymers/commodity/hdpe/properties
c (Reference cost comparison table in article I sent, some of the numbers used in the calculations
came from this table. They will all have the subscript C next to them)

23. - 23 -
Appendix F
Final Prototype Development and Images
Figure 1: Adaptation of Final Design for Prototyping
Figure 2: Vacuum Forming Process Overview
Vacuum
Platen
Buck
Heated Plastic
Oven

24. - 24 -
Figure 3: Prototyping Process (left: vacuum forming in action, right: machined bucks)
Figure 4: Final Prototype Images
Holes for
Suction
Draft angles
to prevent
webbing
Embossed Gum Brand
Cavity for Papers