plastic bottle design

GROUP ONE, LTD.Marc BranderMike Holzer

Benny KirchnerTyrel Ruch

PRODUCT GOALS

PRODUCT GOALS• Design a unique container for a new liquid soap product.• Container needs to hold 28-32 fluid oz. of product.• Container must have a method for seeing remaining product.

PRODUCT GOALS• Container should be aesthetically pleasing.• Container sizing should fit within the “Golden Section,” or a ratio of 1:1.618 width to height.

PRODUCT GOALS• The container must be designed ergonomically to make it useful to its purpose. It must fit the hand, and require only a reasonable amount of force to dispense the product.

PRODUCT GOALS• Provision must be made for application of a customer supplied product label.• The customer would prefer a raised surface on which to affix their label.

MATERIAL SELECTION

MATERIAL SELECTION

Per customer request, the original design specification called for ABS plastic as the material for this bottle.

MATERIAL SELECTION

However, research conducted at our expense has indicated PET (Polyethylene Terephthalate) would be better suited for this product.

MATERIAL SELECTION

Reasons for this material change include:

• Material Property Advantages• Raw Material Cost• Recyclability

MATERIAL SELECTION: MATERIAL PROPERTIES

The material properties of PET offer a distinct advantage to ABS for the following reasons:


1. PET can be produced with 99% optical clarity, compared to 79% with ABS.

2. ABS is a type of styrene known for its durability and impact resistance.


3. Due to its durability and impact resistance, ABS provides a stiffer wall, causing a need for greater force to be exerted in this squeeze bottle application.


4. ABS offers a poor surface finish and requires secondary coating processes to produce a smooth or glossy appearance.


5. PET will produce clear, glossy bottles needing no secondary processes.

6. PET is better suited to both Extrusion Blow Molding and Stretch Blow Molding.

MATERIAL SELECTION:RAW MATERIAL COSTS

PET and ABS are both traded on an open market. For this reason, material pricing for both fluctuates periodically.

MATERIAL:RAW MATERIAL COSTS

Regardless of the fluctuation, virgin PET pellets (raw material) can be obtained at a lower cost than ABS.

MATERIAL:RAW MATERIAL COSTS

Prices Listed are Per Pound

ABS $2.42 $0.83 $1.43 $1.25 $0.66 $0.96 $1.15 $0.68 $0.91 ABS (30% glass) $1.25 $1.25 $1.25 ABS - Medium Impact $0.89 $0.85 $0.87 ABS - High Impact $0.86 $0.86 $0.86 $1.24 $1.24 $1.24 Polcarbonate + ABS $4.25 $3.93 $4.09 $2.60 $0.90 $1.75 Polycarbonate + PET (Imp. Mod) $2.87 $2.87 $2.87 HDPE $0.82 $0.57 $0.67 $0.89 $0.49 $0.72 $0.79 $0.53 $0.64 HDPE (widespec, virgin) $0.42 $0.42 $0.42 HDPE (co-pp) $0.36 $0.36 $0.36 LDPE $0.94 $0.94 $0.94 $0.80 $0.72 $0.76 LLDPE $3.30 $1.40 $2.35 $0.93 $0.93 $0.93 $0.85 $0.50 $0.70 PET $1.50 $1.28 $1.43 $0.67 $0.67 $0.67 $0.70 $0.45 $0.56

Generic High Low Avg. High Low High Low Avg.

Source: IDES Plastics "The Plastics Web." Retrieved 2008-10-23, from http://www.ides.com/resinprice/resinpricingreport.asp

Less than 10,000 lbs. 10,000 - 100,000 lbs. Greater than 100,000 lbs

Avg.

MATERIAL SELECTION: RECYCLABILITY

Re-use and recycling is becoming a major consideration in corporate responsibility in the current global economy.


For this reason, PET is a more sensible choice ecologically, as it is more widely accepted in recycling programs nationwide.


Number 1 PlasticsPET/PETE (Polyethylene Terephthalate)

Found in: Soft drink, water and beer bottles; mouthwash bottles; soap bottles; peanut butter containers; salad dressing and vegetable oil containers.

Source: TheDailyGreen.com http://www.thedailygreen.com/green-homes/latest/recycling-symbols-plastics-460321


Recycling: Picked up through most curbside recycling programs.

Recycled into: Polar fleece, fiber, tote bags, furniture, carpet, paneling, straps, (occasionally) new containers.



PET plastic is the most common for bottles because it is inexpensive, lightweight and easy to recycle. It poses low risk of leaching breakdown products. Recycling rates remain relatively low (around 20%), though the material is in high demand by remanufacturers.



Number 7 Plastics Miscellaneous Found in: Three- and five-gallon water bottles, sunglasses, DVDs, iPod and computer cases, signs and displays, certain food containers, nylon



Recycling: Number 7 plastics have traditionally not been recycled, though some curbside programs now take them.

Recycled into: Plastic lumber, custom-made products



ABS plastic, which is classified as a Number 7, is one of a wide variety of plastic resins that don't fit into any of the other categories.



As an incentive, your own scrap PET or other commercially available recycled PET may be added to your virgin material to produce a cost savings.

PRELIMINARY DESIGN IDEAS

INITIAL DESIGN IDEAS

We considered a number of designs and styles to satisfy your needs. The following are a few of our preliminary design thoughts:

INITIAL DESIGN IDEAS

FINAL DESIGN PROPOSAL

GOLDEN SECTIONThis diagram demonstrates the application of the “Golden Section” of 1.618:1 in the bottles dimensions.

GOLDEN SECTIONAll of the dimensions shown are related to one another using this ratio.

RAPID PROTOTYPING

RAPID PROTOTYPING

Using a Stratysys Dimension SST Rapid Prototyping machine, we were able to create a 1:1 scale 3-dimensional prototype model of our design proposal.

The bottle has been ergonomically designed for easy one handed use.

Using symmetry, the bottle also allows for easy left-hand use.

The bottle shape also allows it to be stood on its top.

COLORATION SUGGESTIONS


Using a third interval color scheme, green, blue green, and blue were added to promote a feeling of harmony.


Using a fifth interval color scheme, green and violet were added to promote a subtle, yet pleasing appearance.


Using a seventh interval color scheme, red and green were used to promote a feeling of excitement.

FORCE ANALYSIS

FORCE ANALYSIS

Using COSMOS Works, a Finite Element Analysis (FEA) software, we were able to simulate the force required to squeeze this bottle to dispense the product within.

FORCE ANALYSIS

Our results were as follows:

FORCE ANALYSIS• Using a squeezing force of only four pounds, the bottle will deform .330 inches per side.

COSMOS – von MISES STRESS

FORCE ANALYSIS• We feel that four pounds of force is a very reasonable amount of force to exert;

COSMOS – DEFORMATION

FORCE ANALYSIS• and that this amount of deformation should provide sufficient internal pressure to dispense the product.

COSMOS – EQUIVALENT STRAIN

VOLUMETRIC REQUIREMENTS

VOLUMETRIC REQUREMENTS

VOLUMETRIC REQUREMENTS

Initial Volume 63.39 Cubic Inches(-) Final Volume 3.99 Cubic Inches

59.40 Cubic InchesConversion Factor 0.5541125541

32.91 Fluid OuncesSource: Online Conversion.com http://www.onlineconversion.com/volume.htm,

based on the formula 1 cubic inch = 0.554 112 554 1 ounce [US, liquid]

BOTTLE CAP

BOTTLE CAP

We designed this bottle to feature an inverted style cap. This style has gained popularity on a wide variety of products, and we feel that it is ideal for this application.

BOTTLE CAP

We have sourced a cap for this bottle from Zeller Plastics, and the cap is available through McKernan Packaging.

BOTTLE CAP

The neck is produced using the PBI L28SP400 finish, and a number of manufacturers offer similar caps in this size.

BOTTLE CAP

This cap, P/N 3812-28400, is available at a cost of $0.57 each in quantities of 1000.

BOTTLE CAP

The cap shown here features a one way silicone valve to prevent drips and to limit flow.

CAP AND THREAD ALIGNMENT DETAIL

ARE THERE ANY QUESTIONS?

THANK YOU.

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