Berry Plastics Liner-less Detergent Cap
About Berry Plastics. Leading manufacturer of injection molded packaging in the U.S.Currently working on new product development around liner-less closuresWith the partnership of UD and our sponsor, John Tauber, a new liner-less detergent cap will be designed. Problem Definition. The current cost of polypropylene is rising causing the cap liners to become more and more expensiveThe cost of the liner is now close to 1/3rd of the total cost to make the capA new design is needed to eliminate t30775
Berry Plastics Liner-less Detergent Cap
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Berry PlasticsLiner-less Detergent Cap
Advisor: Dr. Michael Keefe
Sponsor Contact: John Tauber
About Berry Plastics Leading manufacturer of injection molded packaging in the U.S. Currently working on new product development around liner-less closures With the partnership of UD and our sponsor, John Tauber, a new liner-less detergent cap will be designed Problem Definition The current cost of polypropylene is rising causing the cap liners to become more and more expensive The cost of the liner is now close to 1/3rd of the total cost to make the cap A new design is needed to eliminate the need for a liner The design should be as effective and inexpensive as possible
Affected Customers Liquid detergent companies, i.e. Clorox Retail stores, i.e. Walmart General public Elderly Middle aged Teenagers Problem Specifics
Low Cost Maximum Seal Time Aesthetically Pleasing Easy to Grip Easy to Close Simple Design
Liner-less Design Injection Molded One Piece Applied Torque Metrics and Target Values Gap Size – Area between cap and bottle does not change from current design Cost - < $60 per 1000 caps Appendage Thickness – None Time Until Leak – 1 hr < t < 24hr Reproducibility of Results - > 90% Loss of Fluid – 0 mL Torque Required – τ = 35 in-lbs Benchmark Concepts Solo Cap XTRA Cap Type of seal Wedge seal to spout
Benchmark Concepts cont. All Cap Type of seal Cap lays flat against bottle land; tight tolerance Febreze Cap Type of seal Wedge seal to bottle
Benchmark Cap Leak Testing To determine which concepts work better than others Tested with actual product (detergent) inside Caps tightened to 35 in-lbs Bottles lay flat on their side and checked periodically for leakage Each benchmark tested twice Leak Test Results From Benchmark Caps All- Tied for best XTRA- Tied for best -Strong seal to deformable spout component Febreze- Tied for worst Solo- Tied for worst -Fin offered weak seal with bottle Our Concepts
Two Vertical Fins
Fray out to touch walls when screwed down Force from cap walls and plastic fin resilience create seal with both bottle and spout Problem- Space between outside fins and cap interior is too thin Mold has a high probability to break over time from stress Our Concepts Cont.
Proven easy and successful With proper tolerance cap sits flush on bottle top, creating a tight seal Problem- Tolerance would have to be incredible Top of bottle would have to be consistently manufactured completely flat Our Concepts Cont.
Cap tightens to inside wall of spout while screwing down Allows more surface contact Allows least amount of liquid to directly reach the seal Fluid pushes cap against bottle naturally Primary Cap Design Main Metrics Metric #1- Gap Size (26%) Metric #3- Appendage Thickness (18%) No increases in thickness measured from the base. i.e.- injection moldable Prototype Testing Same testing procedure as before with water No seal lasted 1 hr.
Change in Problem Scope The seal may not be achievable if the bottle was manufactured incorrectly Changing a spec on the bottle itself may be a cheaper and simpler solution than designing a new cap Need to show evidence of the bottle being direct cause of failure before changing specs Bottle Testing Tests of current bottles and liner-less caps from Berry Plastics 16 different bottles/16 different caps for a total of 256 tests Bottles lay flat on
their sides with paper
towel underneath to
Bottle Testing cont. Bottles filled with water
for most extreme testing
Caps torqued to 35 in-lbs
using torque meter
Max time limit of 1 hour Results: 48% success rate Testing Results Bottles show more consistency Bottle Investigation Possible Causes of Failure Bottle land flatness Wall thickness Distance from start of thread to bottle land Correlations More consistent wall thickness promotes a longer seal Flatter Bottles sealed longer
Reaming process impact:
Land distance to thread
Bottle Manufacturer Leak Investigation
Recommendations Implement new bottle specs with old cap design Wall thickness variability- < 0.020 inches Flatness- < 0.010 inches End Lip variability- < 0.005 inches Manufacturer limitations? Create a new cap design Greater wedge angle Same fin from old cap Do both
Questions/Concerns Thank You