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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

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Berry Plastics Liner-less Detergent Cap

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Berry plastics liner less detergent cap

Berry PlasticsLiner-less Detergent Cap

Team 7

Tom Pepe

Ross Rozansky

Dale Heintzelman

Cherish Wilford

Glenn Catlin

Advisor: Dr. Michael Keefe

Sponsor Contact: John Tauber


About berry plastics

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

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

Liner


Affected customers

Affected Customers

  • Liquid detergent companies, i.e. Clorox

  • Retail stores, i.e. Walmart

  • General public

    • Elderly

    • Middle aged

    • Teenagers


Problem specifics

Problem Specifics

Wants

  • Low Cost

  • Maximum Seal Time

  • Aesthetically Pleasing

  • Easy to Grip

  • Easy to Close

  • Simple Design

Constraints

  • Liner-less Design

  • Injection Molded

  • One Piece

  • Applied Torque


Want weights

Want Weights


Metrics and target values

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


Metric weights

Metric Weights


Benchmark concepts

Benchmark Concepts

  • Solo Cap

    • Type of seal

      • Fin seal with bottle

  • XTRA Cap

    • Type of seal

      • Wedge seal to spout

        component

Fin

Wedge


Benchmark concepts cont

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

        spike

Wedge


Benchmark cap leak testing

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

Leak Test Results From Benchmark Caps

  • All- Tied for best

    • -Excellent tolerance

  • XTRA- Tied for best

    • -Strong seal to deformable spout component

  • Febreze- Tied for worst

    • -Flimsy spike design

  • Solo- Tied for worst

    • -Fin offered weak seal with bottle


Our concepts

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

Our Concepts Cont.

Flat Contact

  • 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 cont1

Our Concepts Cont.

Internal Wedge

  • 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

Primary Cap Design

  • Main Metrics

  • Metric #1- Gap Size (26%)

    • Tight fit

  • Metric #3- Appendage Thickness (18%)

    • No increases in thickness measured

    • from the base. i.e.- injection moldable


Prototype testing

Prototype Testing

  • Same testing procedure as before with water

  • No seal lasted 1 hr.

Notch

Wedge


Change in problem scope

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

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

    observe leakage


Bottle testing cont

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

Testing Results

  • Bottles show more consistency


Bottle investigation

Bottle Investigation

  • Possible Causes of Failure

    • Bottle land flatness

    • Wall thickness

    • Distance from start of thread to bottle land


Correlations

Correlations

  • More consistent wall thickness promotes a longer seal

  • Flatter Bottles sealed longer


Bottle manufacturer

Reaming process impact:

Wall thickness

Flatness

Land distance to thread

Bottle Manufacturer


New bottle testing

New Bottle Testing

  • Success rate of 94.4%


Leak investigation

Leak Investigation

Fin

Gap

No Gap


Recommendations

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

Wedge

Fin


Questions concerns thank you

Questions/Concerns Thank You