The document discusses the development of sustainable packaging by Consolidated Container Company, focusing on a case study involving a trigger sprayer bottle redesign to improve fitting in shipping containers. It explores the use of a Packaging Optimization Program (POP) and NX software tools to create efficient designs that meet performance, environmental, and economic criteria. The presentation highlights collaboration and challenges in optimizing bottle dimensions while addressing sustainability goals.

1. Developing Sustainable Packaging using NX John Manderfield Director of Creative Design Consolidated Container Company [email_address]

2. Agenda Welcome Intro to Consolidated Container Role of Shipping Containers Use of Package Optimization Program (POP) to optimize shipping container Case Study: Trigger Sprayer Customer wants new trigger bottle Designed it: does not fit in box Went to POP - developed range of sizes Went back to NX to resize numerous parts to pack out efficiently

3. Agenda NX Tools Used Sketches, Parameters, Expressions Measure Bodies: Associative: remembers volume check Sticky Call-out: shows on screen True Shading NX Tools We Want To Get To Goal Seek: drive height to reach target internal volume UDF: would this help? Reuse Library: common sprayer to all shapes NX Modules To Consider Assemblies Knowledge Fusion: extra cost? Tips & Tricks from Audience? Questions & Answer Session

4. What is “Sustainable” Packaging? Packaging over its life cycle that: Meets society’s needs for performance and quality of life (social) Minimizes life cycle environmental impacts (environmental) Is efficient in how it uses resources (environmental) Is cost effective (economic) Is safe, meets all regulatory requirements and is easy to use (environmental and social) Does not compromise the ability of future generations to meet their needs (economic, environmental and social) Source: Dow Chemical

5. How Does Consolidated Container Contribute? Rigid Packaging Extrusion Blow Molding

6. My Role Director of Creative Design Industrial Design Subject Matter Expert PLM World User Group (past chair) Drive Innovation Recognize Trends… … drive efficient packaging using POP

7. Thinking…Inside the Box

8. Recognizing a Need for Efficiency CCC makes Bottles Shipped to Filler (empty) Filled, Capped, Labeled Boxed in shipping cartons Stacked on pallets Placed inside trailers/containers Shipped to store/DC Placed on store shelf

9. Packaging Optimization Program (POP) Approach TOPS from Tops Engineering Analyzes dimensions of shapes – space fits into other shapes Optimizes for shipping purposes

10. New 22oz Trigger Design Optimized with POP Digital Rendering Submitted to Customer Marketing is OK with it Consumer Focus Group loves it Operations hates it no one asked him Incorrect capacity Does not fit in box Wants a 32oz size as well

11. Using POP to optimize the design

12. POP Inputs: Bottle & ShipCase Analyze with POP

13. POP Inputs: Pallet

14. POP Solution: Graphics

15. POP Solution: Data

16. POP Solution So…what is all this telling me? I just want to get the bottles into the box! The Bottle “fits”… but could fit better

17. Sustainable Design Goal Setting VERSATILE CASE: make two sizes fit same box VOLUME GOAL: 22oz AND 32oz CASE GOAL: Increase Cases 19.84 (too small) Volume (oz) 105 Cases 0% 22oz &32 Trigger Start Part EFFICIENCY GAIN FLEX? TO FROM

18. Bottle Start Part

30. Progression Bottle Optimization

39. Sustainable Design Goal Setting VERSATILE CASE: make two sizes fit VOLUME GOAL: 22oz AND 32oz CASE GOAL: Increase Cases 22 & 32 22 & 32 22 (32 won’t fit) 22 & 32 19.84 (too small) Volume (oz) 14% 120 n/a 2.35” 2.44” Depth 125 125 125 105 Cases 20% TARGET > 1.0” MAX Current Height 20% TARGET 3.65” 3.2” Width 20% NO 2.15” 2.44” Depth 0% 22oz Trigger Start Part EFFICIENCY GAIN FLEX? TO FROM

40. Sustainable Design Goal Setting Increase Width 3.2 to 3.65” Makes bottle larger Increase Height up to 1” Makes bottle larger Decrease Depth 2.44 to 2.15” Makes bottle smaller

41. POP Approach - Limitations POP does not understand complex geometry of the part inside the carton Example: round bottles do not maximize cube of box NX can’t read POP data directly (manual reentry) POP can’t read NX data

42. Wrap Up NX Tools Used Sketches, Parameters, Expressions Measure Bodies: Associative: remembers volume check Sticky Call-out: shows on screen True Shading NX Tools We Want To Get To Goal Seek: drive height to reach target internal volume UDF: would this help? Reuse Library: common sprayer to all shapes NX Modules To Consider Assemblies Knowledge Fusion: extra cost? Tips & Tricks from Audience? Questions & Answer Session

43. Exploration of Bottle Designs Rendered with Basic Shading

44. Exploration of Bottle Designs Rendered with Basic Shading

45. Exploration of Bottle Designs Rendered with NX True Shading <1 min & real time w/Shape Studio

46. Developing Sustainable Packaging using NX Thanks to: John Krzysik, Design Engineer, Consolidated Container For his support of this presentation