Developing SustainablePackaging using NX

John ManderfieldDirector of Creative DesignConsolidated Container Companyjohn.manderfield@cccllc.com

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Agenda

• Welcome• Intro to Consolidated Container• Role of Shipping Containers• Use of Package Optimization Program (POP) to

optimize shipping container• Case Study: Trigger Sprayer

– Customer wants new trigger bottle– Designed it: does not fit in box– Went to POP - developed range of sizes– Went back to NX to resize numerous parts to

pack out efficiently

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Agenda

• NX Tools Used– Sketches, Parameters, Expressions– Measure Bodies:

• Associative: remembers volume check• Sticky Call-out: shows on screen

– True Shading• NX Tools We Want To Get To

– Goal Seek: drive height to reach target internal volume

– UDF: would this help?– Reuse Library: common sprayer to all shapes

• NX Modules To Consider– Assemblies – Knowledge Fusion: extra cost?

• Tips & Tricks from Audience?• Questions & Answer Session

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What is“Sustainable” Packaging?

Packaging over its life cycle that:

• Meets society’s needs for performance and quality of life (social)

• Minimizes life cycle environmental impacts (environmental)• Is efficient in how it uses resources (environmental)• Is cost effective (economic)• Is safe, meets all regulatory requirements and is easy to use

(environmental and social)• Does not compromise the ability of future generations to meet

their needs (economic, environmental and social)– Source: Dow Chemical

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How Does Consolidated Container Contribute?

• Rigid Packaging• Extrusion Blow Molding

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My Role

• Director of Creative Design• Industrial Design• Subject Matter Expert• PLM World User Group (past chair)• Drive Innovation• Recognize Trends…

…drive efficient packaging using POP

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Thinking…Inside the Box

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Recognizing a Need for Efficiency

• CCC makes Bottles• Shipped to Filler (empty)• Filled, Capped, Labeled• Boxed in shipping cartons• Stacked on pallets• Placed inside trailers/containers• Shipped to store/DC• Placed on store shelf

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Packaging Optimization Program (POP) Approach

• TOPS from Tops Engineering• Analyzes dimensions of shapes –

space fits into other shapes• Optimizes for shipping purposes

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New 22oz Trigger DesignOptimized with POP

• Digital Rendering Submitted to Customer

• Marketing is OK with it• Consumer Focus Group

loves it• Operations hates it

– no one asked him– Incorrect capacity – Does not fit in box– Wants a 32oz size as well

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Using POP to optimize the design

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POP Inputs: Bottle & ShipCase

• Analyze with POP

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POP Inputs: Pallet

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POP Solution: Graphics

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POP Solution: Data

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POP Solution

• So…what is all this telling me?• I just want to get the bottles into the box! • The Bottle “fits”…but could fit better

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Sustainable Design Goal Setting

• VERSATILE CASE: make two sizes fit same box• VOLUME GOAL: 22oz AND 32oz• CASE GOAL: Increase Cases

FROM TO FLEX? Cases Volume(oz)

EFFICIENCYGAIN

Start Part

22oz &32 Trigger 105 19.84(too small)

0%

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Bottle Start Part

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ProgressionBottle Optimization

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Sustainable Design Goal Setting

VERSATILE CASE: make two sizes fit

VOLUME GOAL: 22oz AND 32oz

CASE GOAL: Increase Cases

FROM TO FLEX? Cases Volume(oz)

EFFICIENCYGAIN

Start Part

22oz Trigger 105 19.84(too small)

0%

Depth 2.44” 2.35” n/a 120 22 & 32 14%

Depth 2.44” 2.15” NO 125 22 (32won’t fit)

20%

Width 3.2” 3.65” TARGET 125 22 & 32 20%

Height Current > 1.0” MAX

TARGET 125 22 & 32 20%

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Sustainable Design Goal Setting

Increase Width3.2 to 3.65”

Makes bottle larger

Increase Heightup to 1”

Makes bottle larger

Decrease Depth2.44 to 2.15”

Makes bottle smaller

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POP Approach - Limitations

• POP does not understand complex geometry of the part inside the carton– Example: round bottles do

not maximize cube of box

• NX can’t read POP data directly (manual reentry)

• POP can’t read NX data

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Wrap Up

• NX Tools Used– Sketches, Parameters, Expressions– Measure Bodies:

• Associative: remembers volume check• Sticky Call-out: shows on screen

– True Shading• NX Tools We Want To Get To

– Goal Seek: drive height to reach target internal volume

– UDF: would this help?– Reuse Library: common sprayer to all shapes

• NX Modules To Consider– Assemblies – Knowledge Fusion: extra cost?

• Tips & Tricks from Audience?• Questions & Answer Session

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Exploration of Bottle DesignsRendered with Basic Shading

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Exploration of Bottle DesignsRendered with Basic Shading

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Exploration of Bottle DesignsRendered with NX True Shading<1 min & real time w/Shape Studio

Developing SustainablePackaging using NX

Thanks to:John Krzysik, Design Engineer, Consolidated ContainerFor his support of this presentation