Systematic Packaging Development Relation to product design

Transcription

1 Systematic Packaging Development Relation to product design CHEM-E2160 Product Development Practices J. Paltakari Systematic packaging development PACKAGING 2 1

2 Basic functions of packaging Includes a product right amount items, weight, volume Basic functions of packaging Protect and conserve the product and the environment Mechanical stresses (vibration, shocks) Atmospheric conditions (light, air/gases) Improves hygiene! Also protect environment from the product (hazardous products/goods)! 2

3 Basic functions of packaging Provide effective production and good handling during all phases in logistic chain Rational handling possible Improves consumer safety Makes standardising possible Handling and packaging with suitable machinery Minimise product losses Basic functions of packaging Be informative and promote product sales Appearance; sell the product (the 2 seconds) Instructions for operation and use Legislation; obligatory product information 3

4 Modular dimensions 7 Shocks and vibration Pile resonance and vibration 8 4

5 Stack edge load 9 Development stages A. Determine stresses in the distribution environment and chain B. Determine product fragility and sensitivity C. Feedback to product development product improvement D. Choice of packaging material E. Design and manufacture of prototype packaging F. Testing the prototype packaging 10 5

6 Product categories 1 Everyday commodities, pharmaceuticals and inexpensive products can not justify added costs of cushioning Canned food Dried and frozen food Juice and dairy products Medicines and techno-chemical products Phases A, D, E, F of systematic packaging development applied 11 Development stages (cat 1) A. Determine stresses in the distribution environment and chain B. Determine product fragility and sensitivity C. Feedback to product development product improvement D. Choice of packaging material E. Design and manufacture of prototype packaging F. Testing the prototype packaging 12 6

7 Product categories 2 High value products can carry added costs of cushioning Electronic devices Telecom products Computers Optical instruments Medical equip. and instruments Precision tools, etc. All six phases of systematic packaging development applied 13 A) Determine stresses in the distribution environment and chain Mechanical shocks, vibration, compression Climate temperature, humidity Physical ESD, electromagnetic radiation, magnetic fields Chemical gases, fluids Biological bacteria, bugs, fungus Other dust, sand, water 14 7

8 B) Determine product fragility and sensitivity Vibration Vibration tests Identify resonance frequencies (acceleration vs. resonance frequency) Shocks Shock tests Damage boundary curve (acceleration and velocity) 15 B) Determine product fragility and sensitivity Vibration 16 8

9 B) Determine product fragility and sensitivity Shocks Damage boundary curve Damage area

10 The critical impact velocity (ΔVc) Simulating impact or drop of a product caused by improper handling of the end user, of which the impulse is short by ASTM D3332, the impulse is normally less than 3ms. The lab generates a half-sine wave with low impact velocity by the mechanical impact machine, accompanied by a short impulse time (normally less than 3ms), upon the product. The test goes on in this manner with gradually increased impact velocities until the product is damaged the critical design velocity ΔVc of the product. Outcome: the sustainable impact velocity and the limit of drop height can be determined for the product in the unpacked condition. 19 The critical impact acceleration (ΔAc) Simulation of strength capability of the product against a mechanical shock / free fall drop during the transportation helps identifying the packaging cost for an optimal buffering protection for the product. a force of low acceleration generated by mechanical impact machine in a stepping wave upon the product The test goes on with gradually increased impact acceleration until the product is damaged the critical design acceleration ΔAc of the product. Outcome: Data is provided to the packing designer for an optimal packing design as well as the reference basis for carrying out drop test of the packing

11 C) Feedback to product development product improvement Weaknesses in the product construction are corrected in this step (as regard to dynamic stresses) Effect of constructional changes is assessed and evaluated Trade-off between product improvement costs, product reliability and packaging costs evaluation and ranking for effectiveness and competitiveness 21 C) Feedback to product development economic evaluation Costs vs Savings Product Product Packaging Improved Product Packaging 22 11

12 D) Choice of packaging material Product protection against mechanical stresses Vibration Shocks Taking into consideration: Economy Environment 23 Vibration attenuation amplification/attenuation curve = worst case! 24 12

13 . The amplification/attenuation curve defines the frequencies at which a cushion material will amplify vibrational input and the frequencies at which it will filter out or attenuate the vibration. One amplification/attenuation curve is generated for each material type and material thickness combination. Resonance frequency vs static stress 26 13

14 Cushion curves A shock cushion curve describes the material in terms of the deceleration transmitted to an object falling on that material at different static loadings. One cushion curve is generated for each material type, material thickness and drop height combination. 27 Systematic packaging development and optimal product design Distribution environment Product Packaging Ideal packaging and product design Product Packaging Under-packaging Transport damage Product Packaging Over-packaging -Environmental load -Waste of resources Improved Product Packaging Optimal packaging and product design -Protection -Economy -Environmental load 28 14