1 L2 Product Design 1

7/30/2019 1 L2 Product Design 1

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Product Design

25% of ChEs work on Products,

not Processes

Chapter 1, 2

Article on Product Design

CH EN 4253Terry A. Ring


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ChE

Education


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Chemical Products


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Products Are Everywhere

But, how are they designed? Formulated Products

Engineered Products

Lets look at some examples. What are the ingredients?

What are the ingredients used for?

What are the characteristics of the product? What is the science behind the product?

Why is this product desirable?

Why does the product sell?


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Engineered Products

Hemodialysis Device

Hand Warmer

Fe Powder Heat Patch

Fe + C Powders

Solar Desalination Unit for Home

Zap PakHeat Pack Aroma/Insect Repellant Wall Plugs

Alcohol Fuel Cells


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Hemodialysis Device


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Hemodialysis

Counter Current (Shell & TubeHX design) Membrane

Blood

DI Water

Series of Resistances

Mass Transfer

Blood

Water

Diffusion in Membrane

Urea Byproducts


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Home Desalination Unit

Transparent Cover

Allows Sunlight in

Condenses Vapor

Salt Soln

H2O


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Heat Patch/Hand Warmer

4Fe(s) +3 O2Fe2O3

+ H

H = -824.2 kJ/moloxide

Graphite (dilutent+

shelf life)

NaCl Catalyst Control Kinetics of

Reaction


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Zap Pack

Heat of Crystallization

NaC2H3O2*3H2O

-4.7 kcal/mole Na2S2O3*5H2O

-11.4 kcal/mole

Ca(NO3)2*4H2O

-8.0 kcal/moleCl

T

eq

Solid-Liquid

Line

Meta-stableSolid


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Zap Pack

Step1:Activate byflexing metaldisc

Step 2: Liquidcrystallizingand heating

Step 3: Pad ishot and ready

for use

The clever bit is that thereaction

isreversible by just boiling the thing in water
http://www.china-toy-factory.com/http://www.china-toy-factory.com/http://www.china-toy-factory.com/http://www.china-toy-factory.com/


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Air Freshener

Oil mixture

Heated

Selective Evaporationof oil mixture

Partial Pressure as a

function of

Temperature


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Direct methanol Fuel Cell

PEM Fuel Cell

With Special Catalyst

Anode (oxidation)


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Formulated Products

Lets look at some examples.

What are the ingredients?

What are the ingredients used for?

What are the characteristics of the product?

What is the science behind the product?

Why is this product desirable?Why does the product sell?


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Formulated Products

Toothpaste

Shampoo

Deodorant

Mouthwash

Dish soap


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Active Ingredients Sodium

monofluorophosphate

0.76% Inactive Ingredients

Glycerin

Sorbitol

Hydrated silica

Propylene glycol Sodium bicarbonate

Aluminum oxide

Water

Pentasodium triphosphate

Tetrasodium pyrophosphate

Sodium lauryl sulfate

Flavor

sodium hydroxide

calcium peroxide

Sodium saccharin Carrageenan

cellulose gum

titanium dioxide

Note; Bingham Plastic Rheology


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Active Ingredients Sodium fluoride 0.24%

Inactive Ingredients Water Glycerin

Sorbitol

Hydrated silica Pentasodium

triphosphate

Sodium lauryl sulfate

Flavor

Tetrasodiumpyrophosphate

PVM/MA copolymer Sodium hydroxide

Cellulose gum

Sodium saccharin

Carrageenan Polyethylene

Titanium dioxide

FD&C blue no. 1


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Active Ingredients

Sodium fluoride 0.25%

Inactive Ingredients Sorbitol

Sodium bicarbonate

Hydrated silica

Glycerin

Water

Tetrasodium

pyrophosphate

Sodium lauryl

sarcosinate

Flavor

Sodium saccharin

Cellulose gum Sodium lauryl sulfate

Titanium dioxide


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Mouthwash

Active Ingredients Thymol 0.064%

Eucalyptol 0.092%

Methyl Salicylate 0.006% oil of wintergreen

Menthol 0.042%

Also Contains Water

Alcohol 26.9%

Benzoic Acid

Poloxamer 407

Sodium Benzoate

Caramel


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Definitions

Disinfectants antimicrobial agents that are applied to non-living objects to

destroy microorganisms.

Kill > 99.9999% Sanitizer

substances that reduce the number of microorganisms to a safelevel. One official and legal version states that a sanitizer must becapable of killing 99.999%, known as a 5 log reduction, of aspecific bacterial test population, and to do so within 30 seconds.

Antiseptics Antiseptics destroy microorganisms on living tissue.


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Deodorant Active Ingredients

Aluminum ZirconiumTetrachlorohydrex glycincomplex

Inactive Ingredients Water Cyclomethicone

SD alcohol40

Tripropylene glycol

Dimethicon Propylene Glycol

Phenyl trimethicone

PEG/PPG-18/18

Dimethicone

Fragrance


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Shampoo Ingredients

Water

PEG-80

Sorbitan laurate

Cocamidopropyl betaine

Sodium trideceth sulfate

Glycerin

Lauroamphoglycinate

PEG-150 distearate

Sodium laureth-13 carboxylate

Fragrance polyquaternium-10

Tetrasodium EDTA

Quaternium-15

Citric Acid

D&C Yellow No. 10

Orange No. 4


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Shampoo Ingredients

Water

Ammonium Lauryl sulfate

Ammonium laureth sulfate

Ammonium chloride

Cocamide MEA

Fragrance

PEG-5 cocamide

Hydroxypropyl methylcellulose

Tetrasodium EDTA

DMDM hydantoin

Citric Acid

Tocopheryl Acetate (Vitamin E Acetate)

PPG

Methylchloroisothiazolinone

Apple Extract

Ethylisothiazolinone

Glycerin

FD&C Yellow No. 5, Blue No. 1


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Body Shop Natural Shampoo

Ingredients Water

Sodium Laureth sulfate

Cocamidoproply betaine

Cvocamide DEA Coco-Glucoside

Perfume

Phenoxyethanol laureth-2

Benzyl Alcohol

Sodium Benzoate

Propylene glycol

Citric Acid

Polyquarternium-10

Methylparaben

Agave extract

Benzophenone-4

Disodium EDTA Bladderwrack powder

Butylparaben

Ethylparaben

Isobutylparaben

Propylparaben Potassium sorbate

Peony Extract

D&C No. 5


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Packaging attracts the customer

Package Needs

Name of Product

Sales Pitch

How to use

Warnings

Size (wgt. or vol.) of

package

Ingredients List Product Safety Info.

Who to call for info. and

Help


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Product Characteristics

Color

Taste

Smell Feel

Rheology

Surface tension

Adhesion

Other

What makes the productdesirable? To whom?

What is the productscompetition?

What makes it better thanthe competition?

What makes it profitable? Price to produce? Cost of marketing

Profit margins

Middle men (Sales Reps.)

Retail Outlet


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Ingredients

Commercial Availability Multi-source

Quality

Impurities Price

Quantities Available

Packaging

Necessary for theformulation?

What Concentration?

Any difficulty in theprocess? Easy to mix

Packaging made easy Anti-ageingShelf

life


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Product Description

Quality Factors

Use Factors

Materials Factors

Process Factors


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Chemical

Product

Pyramid

Figure of Merit


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Drug Cream Formulation

Shear force during application


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Drug Cream Formulation

Ingredients

Drug

Oil - dissolves drug

Water

Surfactant to stabilize emulsion

FragrancePreservativekeeps bacteria from growing in

formula


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Drug Cream Figure of Merit

Interest Factors

Drug moves from oil in emulsion through water phase

into blood J=(D/)(Co/Kd-0) Ficks 1

st Law

Kd=Co/Cw Distribution Coeff

=(e Vhand Whand/(2 Papp))1/2 Reynolds Equation

Easy to apply Lubrication theory

Friction Coefficient = (e Vhand /(2 Papp Whand))1/2

Figure of Merit = High Flux, low friction

hande

1/2

handapphande

o

V

2

))WP/(2V(

)/)(C(D/

d

appodM

K

PDCKF


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FM Values

Formulation FM Cost ($/kg)

Formulation 1 0.1 20

Formulation 2 120 82

Formulation 3 2 22


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Example-1

Ice CreamQuality Factors

Flavor Creaminess

Smoothness

Coldness

Flavor controlled by Ingredients

Partial Pressure of Flavinoids toNose

Creaminess

Controlled by processing conditions

Ingredients

Smoothness Controlled by

Processing condition Ice Crystals less than 100 microns

Ingredients Fat, air bubbles

Coldness Controlled by

Product Temperature


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Example - 2

Fragrance

Olfactory Factors

Quality factors Impact (in first moments) - relative volatility and

sensitivity of nose (detection threshold)

Diffusion distance soon after opening

Tenacity - distance long after opening

Volumehow many of different sensors in nose are

affected long after opening


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Process to develop a New Product

Stage Gate Methodology Set targets that the Product must meet

E.g. New Refrigerant must have Carnot efficiency of X% or coefficient of performance ofY%

Meet target with several new refrigerants by given date

New refrigerant must not be corrosive to materials of constructioncorrosion tests doneby given date

New refrigerant can be used for a long time with certain polymer sealslifetime testsdone by given date

Environmental disposal questions settled by given date

Impact on Ozone in high atmosphere settled by given date

Production costs evaluated by given date

Potential price and sales volume evaluated by marketing department by given date

EPA (or other government agency) RegistrationBuild plant to manufacture

investment funding, design, construct, debottleneck, run

Steps allow go/no go decisions by management at various Stage Gate Reviews


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After a production process is running

Program of quality control and constant

product improvement

Six Sigma

ISO-9000


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Cost of Defects

Six-Sigma No. of defects per million

3.4/million (6 sigma)

1,350/million (3 sigma) 308,770/million (1 sigma)

Costs Single product

Assembled product

Failure per part Total Failure of Assembly

Importance of Failure

Shampoo

Car

Spaceship

Costs Lost production

cost to produce

Rework cost

Lost Sale Ship back cost

Loss of Customer

Failure in Service Damage to property

Personal Injury

Lost of Life


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6 sigma design

Define Project(Gantt Chart) Steps

Time needed

Allocate Resources

Identify Product

Requirements Select ProductConcept

Develop Product Design Test Competing Designs

Plan Product Manufacture

Quality Assurance Estimate process Variance

determine sigma

Implement Design Pilot Scale

Verify Manufacturability Verify Quality

Verify Profitability

Full Scale


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Getting a Product Approved

FDA

Foods

Drugs

DOT

Shipping

Spills

fires

MSDS

EPA

Disposal or spill

Waste water

Air quality


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MSDS

Section I. Material Identification:

Chemical Name CAS# Wt%

Copper sulfate penta-hydrate 7758-99-8 5

Comments: Product is an aqueous solution of copper sulfate and also

contains stabilizing agents.


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Section II. Physical Data

Physical State: Blue-green liquid

Boiling Point: 212 F (100 C)

Melting Point: Not applicable

Specific Gravity: 0.995

Solubility in water: Not Applicable

Solubility in other solvents: Soluble inmethanol, glycerol and ethanol.

Appearance: Blue-greenliquid.

Odor: Odorless


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Section III. Fire and Explosion Data

Flash Point: Not applicable

Flammability Limits: Not Flammable. If heated and boiled awayto crystals, it can decompose above 400 C and emit toxic copperoxide and sulfur fumes. Above 500 C it emits SO2 fumes.

Extinguishing Media: Does not burn or support combustion. Usewater, CO2 or dry chemicals.

Special Fire Fighting Instructions: If water is used it will becontaminated with copper sulfate and care should be taken to besuch water out of streams and other bodies of water.

Fire and Explosion Hazards: None


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Section IV. Reactivity Data

Stability: Stable

Conditions to Avoid: Dilution of product into streams or otherbodies of water.

Incompatibility: Solution is mildly corrosive to steel. Storesolution in plastic or rubber or 304, 347 or 316 stainless steel.

Hazardous Decomposition Products: None at normal conditions.If dried crystals are heated above 400C toxic fumes of copper

oxide and sulfur may evolve.

Polymerization: Will not occur.


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Section V. Health and Hazard Information

Swallowing: Toxic orally in accordance with FHSLA regulations.Oral toxicity LD59 (male rats) = 3.44 gm/kg.

Skin: Non-toxic. Avoid contact with skin. Non-irritant(rabbit)

Eyes: Causes moderate, but temporary eye irritation.

Inhalation: Inhalation of mist may cause irritation to the upperrespiration tract.

Carcinogenicity: None as per NTP, OSHA and IARC


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Section VI. First Aid Procedures

Swallowing: Give large amounts of milk or water. Inducevomiting. Call Poison Control Center or a physician.

Skin: Wash thoroughly with soap and water. Remove andwash contaminated clothing before reuse.

Eyes: Immediately flush eyes with plenty of water for 15minutes. Hold eyelids apart during irrigation. Call physician.

Inhalation: Remove person to fresh air and call aphysician.

Carcinogenicity: None


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Section VII. Handling Precautions

Personal Protective Equipment: Chemical Safety Goggles

Rubber gloves and rubber apron may be worn.

Ventilation: TWA = 1 mg/l for copper sulfate. When TWAexceeds this limit in the work place, provide appropriate

ventilation. Wear an approved respirator for mists:

MSHA/NIOSH approved number prefix TC-21C, or a NIOSH

approved respirator with any R, P or HE filter.

Alternatively, provide respiratory protection equipment in accordance

with Paragraph 1910.134 of Title 29 of the Code of Federal

Regulations.


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Section VIII. Environmental and

Disposal Information Aquatic Toxicity:

LC50, 24 hours, Daphnia magna = 0.182 mg/l.

Rainbow trout = 0.17 mg/l.

Blue Gill =1.0 mg/l.

All values are expressed as Copper sulfate pentahydrate. Test water was soft.

Spills and Leaks: Comply with Federal, State and local regulations onreporting spills. Do not wash away spilled solution. Collect and treat solution byreacting with soda ash to form an insoluble copper carbonate solid that can bescooped up.

Waste Disposal: Comply with Federal, State and local regulations on wastedisposal. React solution with soda ash to form an insoluble copper carbonate solidthat can be disposed of in an approved landfill.

Environmental Effects: May be dangerous if it enters public water systems.Follow local regulations. Toxic to fish and plants. Fish Toxicity critical concentrationis 235 mg/l and plant toxicity is 25 mg/l both expressed as copper sulfate pentahydrate.


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Section IX. Special Precautions

Storage: Store in a cool, dry, well-

ventilated area. Do not freeze.

Other Precautions: Keep this product and

all other chemicals out of childrens reach.

Section X. Regulatory Information


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Section XI. Shipping Information

DOT Shipping Name: Corrosive

Liquid, N.O.S. (Contains copper sulfate).

Primary Hazard Class/Division: 8

UN/NA number: 1760

Packing Group: III

Marine Pollutant ERG 171.


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Section XII. Other Information

NFPA Codes:

Health:2 Fire: 0 Reactivity: 0

HMIS Codes:

Health: 2 Fire: 0 Reactivity: 0 Protection: B

Section XIII. MSDA PreparationInformation


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Product Innovation Equation

Innovation = insight + ideas + impact

Companies are increasingly making innovationpart of their culture and corporate strategy.

Ideas need SUN behavior Suspend judgment, Understand the idea, Nurture italong

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