Berry Plastics Liner-less Detergent Cap .

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About Berry Plastics. Driving maker of infusion shaped bundling in the U.S.Currently chipping away at new item improvement around liner-less closuresWith the association of UD and our backer, John Tauber, another liner-less cleanser top will be outlined. Issue Definition. The present expense of polypropylene is rising bringing on the top liners to end up more expensiveThe expense of the lin
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Berry Plastics Liner-less Detergent Cap Team 7 Tom Pepe Ross Rozansky Dale Heintzelman Cherish Wilford Glenn Catlin Advisor: Dr. Michael Keefe Sponsor Contact: John Tauber

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About Berry Plastics Leading producer of infusion formed bundling in the U.S. Right now chipping away at new item improvement around liner-less terminations With the association of UD and our support, John Tauber, another liner-less cleanser top will be planned

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Problem Definition The present cost of polypropylene is rising making the top liners turn out to be increasingly costly The cost of the liner is currently near 1/3 rd of the aggregate cost to make the top another outline is expected to wipe out the requirement for a liner The outline ought to be as viable and reasonable as conceivable Liner

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Affected Customers Liquid cleanser organizations, i.e. Clorox Retail stores, i.e. Walmart General open Elderly Middle matured Teenagers

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Problem Specifics Wants Low Cost Maximum Seal Time Esthetically Pleasing Easy to Grip Easy to Close Simple Design Constraints Liner-less Design Injection Molded One Piece Applied Torque

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Want Weights

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Metrics and Target Values Gap Size – Area amongst top and container does not change from ebb and flow configuration Cost - < $60 per 1000 tops 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

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Metric Weights

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Benchmark Concepts Solo Cap Type of seal Fin seal with jug XTRA Cap Type of seal Wedge seal to gush segment Fin Wedge

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Benchmark Concepts cont. All Cap Type of seal Cap lays level against container arrive; tight resistance Febreze Cap Type of seal Wedge seal to jug spike Wedge

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Benchmark Cap Leak Testing To figure out which ideas work superior to anything others Tested with real item (cleanser) inside Caps fixed to 35 in-lbs Bottles lay level on their side and checked occasionally for spillage Each benchmark tried twice

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Leak Test Results From Benchmark Caps All-Tied for best - Excellent resilience XTRA-Tied for best - Strong seal to deformable gush segment Febreze-Tied for most noticeably bad - Flimsy spike configuration Solo-Tied for most noticeably bad - Fin offered feeble seal with jug

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Our Concepts Two Vertical Fins Fray out to touch dividers when screwed down Force from top dividers and plastic balance strength make seal with both jug and gush Problem - Space between outside blades and top inside is too thin Mold has a high likelihood to break after some time from stress

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Our Concepts Cont. Level Contact Proven simple and fruitful With appropriate resilience top sits flush on jug beat, making a tight seal Problem - Tolerance would need to be extraordinary Top of container would need to be reliably fabricated totally level

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Our Concepts Cont. Interior Wedge Cap fixes to inside mass of gush while screwing down Allows more surface contact Allows slightest measure of fluid to straightforwardly achieve the seal Fluid pushes top against jug actually

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Primary Cap Design Main Metrics Metric #1-Gap Size (26%) Tight fit Metric #3-Appendage Thickness (18%) No increments in thickness measured from the base. i.e.- infusion pliant

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Prototype Testing Same testing methodology as before with water No seal endured 1 hr. Score Wedge

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Change in Problem Scope The seal may not be achievable if the jug was fabricated inaccurately Changing a spec on the container itself might be a less expensive and less difficult arrangement than planning another top Need to show proof of the jug being immediate reason for disappointment before evolving specs

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Bottle Testing Tests of ebb and flow jugs and liner-less tops from Berry Plastics 16 unique jugs/16 distinct tops for a sum of 256 tests Bottles lay level on their sides with paper towel underneath to observe spillage

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Bottle Testing cont. Bottles loaded with water for most extraordinary testing Caps torqued to 35 in-lbs using torque meter Max time farthest point of 1 hour Results: 48% achievement rate

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Testing Results Bottles indicate more consistency

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Bottle Investigation Possible Causes of Failure Bottle arrive levelness Wall thickness Distance from begin of string to container arrive

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Correlations More predictable divider thickness advances a more extended seal Flatter Bottles fixed longer

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Reaming process affect: Wall thickness Flatness Land separation to string Bottle Manufacturer

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New Bottle Testing Success rate of 94.4%

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Leak Investigation Fin Gap No Gap

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Recommendations Implement new jug specs with old top plan Wall thickness changeability < 0.020 inches Flatness-< 0.010 inches End Lip inconstancy < 0.005 inches Manufacturer confinements? Make another top plan Greater wedge point Same balance from old top Do both Wedge Fin

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Questions/Concerns Thank You

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