IPD Final Presentation-2
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The group presented their research on developing an alternative material infant mealtime product set to replace plastic. They explored bagasse (sugar cane byproduct), polylactic acid, bamboo, and cork. Prototypes were tested and focus groups with mothers provided feedback. Bagasse was selected for the plate due to its microwavability, affordability and natural material. Financial projections estimated an NPV of $12.7M and 81.9% IRR. Next steps include further prototyping and testing based on focus group feedback, developing a marketing strategy, ramping up manufacturing, and conducting consumer testing.
IPD Final Presentation-2
- 1. Alternative Materials for Infant Mealtime Products By: Sean Dunn, George Ferko, Shannon Fitzpatrick, Ashley Kamauf, Binay Patel, and Susan Sebelsky Presenter : Shannon 1
- 2. Outline • I. Company Background (Shannon) • II. The Problem (Shannon) • III. Materials Selection (Ashley) • IV. Design Evolution (Sean) • V. Testing (Binay and Susan) • VI. Manufacturing (George) • VII. Financials (Binay) • VIII. Future Steps (Susan)
- 3. Background on Playtex • Playtex Products, Inc. is a leading manufacturer of feminine, skin, and infant care products.
- 5. The Problem – Customer needs Ceramic Microwave Plastic Customer Needs • Toxin-free • Affordable • Aesthetically attractive • Sustainable • Eco-friendly • Dishwasher safe • Microwavable Currently, parents who use plastic dishes will heat the food on ceramic dishes first.
- 6. Mission Statement • Our mission is to create a mealtime set that is: – microwave safe – non-breakable – free of harmful chemicals • The set will: – implement the alternative materials that we have researched – provide a safer, more efficient way for parents to feed their 9-18 month old children
- 8. Bagasse Material • All-natural fiber that is a byproduct of the sugar cane refining process Industry • A substitute for Styrofoam in the production of disposable plates • Widely available from countries such as the US, Brazil, and China Our Testing/Evaluation • Passed drop testing • Passed stain testing after 1-3 cycles • Why not just use paper? – Environmentally sound substitute for trees – It does not require bleaching, is highly recyclable, and is also highly biodegradable 8Presenter : Binay
- 9. PLA Material • Made from corn or other starch based products • Thermoplastic polyester • Biodegrades in less than 90 days Industry • Manufactured by blow molding, injection molding, thermoforming, and direct extrusion Our Testing/Evaluation • Passed drop test • Failed stain test (Low grade PLA) • Microwavable and dishwasher safe • FDA food safe Presenter : Ashley 9
- 10. Bamboo Material • Very high sustainability • Imported from China and Vietnam Industry • Processing – Stripping – Sugar and moisture removed – Pressed with water – Laminated into bulk shape – Finishing Our Testing/Evaluation • Breakage in drop testing has led to investigation of different constructions • Staining variability • Bite test results exceeding CPSC requirements Presenter : George 10
- 11. Cork Material • Harvested from trees • Renewable, recyclable, and reusable • Biodegradable Industry • Boiled to remove impurities • High elasticity and compressible Our Testing/Evaluation • Passed drop test • Passed stain test • Microwavable and dishwasher safe • FDA food safe Presenter : Sean 11
- 12. Concept Generation Presenter : Susan 12 HOLD FOOD CLEAN FOOD HOLDER HEAT FOOD HOLDING UTENSILS KEEP HOLDERS STRUCTURE OF ENJOYABILITY/FUN STORAGE OF HOLDER STATIONARY FOOD plate/bowl dishwasher microwave n-shaped magnets compartments colorful switch containers tray hand washing stove top motor powered tray with snap in slots connectable bowls flashing lights lids hollowed out fruit throw away exothermic reaction interchangable head suction cups reward on the bottom music removable bag that ziplocs fishbowl removable surface toaster oven/toaster squirter system sticky surface rotating system cartoon characters throw it out box compressed air lid=microwave glove for eating with hands friction small portions glitter nesting bowls/plates basin high pressure water warm plate bracelet adhesive layers interactive buttons stackability boot bleach rotation legos outer ring placemat with section themed set foldable sack ammonia nuclear skewer to poke food weights pyramid give you compliments shrinkable animal shell brushes (wire/plastic) hamster lock in to plate wider bottom cutout shapes prize at the bottom utensils could pop into back of plate syringe gritty cleansers rotation grips rubbery bottom maze tv on the surface collapsable edible container windshield wiper light magnets velcro adjustable compartments stickers blow up/inflatable bowl/plate in one hoover vacuum heat lamp end wider sand weighing it down hot/cold compartments fun shapes plate as lid for bowl water heater tongue blow dryer moldable handles interlocking blocks rearrangable parts transformers interlocking bag gravity car exhaust resting holder hooks over the table v-shaped bowl live fish/sea animals inside magnetic to mat hand sprinkler dragon fire flat/curved rubber mats interlocking parts legos interlocking blocks levitation toothbrush double boiler looped ends textured mobile train set roll up mind bacteria/microorganism electrical current adhesion to hands placemat with slots solar system plates transparent hooks water suspension chemical solution laser memory foam handles suction tower or containers radio suction cups vacuum self-cleaning thermo-chemical reaction over fingers brakes pumping mechanism tell a story vase (decorative) bag turbo spin cycle grill elastic to attach to set pulley system automated dispenser slip and slide stick to the ceiling air suspension (wind) steam cleaning pig roast style mechnical wings necklace insulation curly doctor's office thing flatten fire truck only rinsing solar panel gel filled handle fun tack catapult sports goal in mouth invisibility police car oxidation sun suction poster mounts orbiting catapult levitation to the storage location space shuttle loofah hot plate duct tape glue conveyor belt animal faces twisting mechanism (like laundry) helmet water gun heating sleeve feeding tube static electricity suspended in gelatin disney princess hangability catapult wipes open flame hold with mind vacuum seal cars/trucks water heater car wash bunsen burner train shaped duct tape fish/Nemo force field crock pot clamp astro-turf body body heat vacuum food themed THINGS TO AVOID bake/broil baseball/sports 90 degree angles oil/gas color changing small gaps photo inserts on the bottom
- 13. First Prototype
- 14. – Plate • Decreased volume – Less material – Lower cost • Large diameter – Increases surface area for easier eating • Deeper compartments – Holds more food • Higher edges to prevent spilling Design Improvements
- 15. Second Prototype
- 16. – Plate Holder • 36% wider to provide stability • 136% higher to accommodate more plates and prevent spills • Modifications to finger holes Design Improvements
- 17. Final Design
- 18. Ergonomics – Unique Features •Plate holder •Finger holes to make it easier for parents to remove plates •Unique base made specifically for Playtex plate, giving the system more stability
- 19. Ergonomics – Unique Features • Fork/Spoon handle • Flexible n-shaped handle makes holding fork/spoon easier for infants • Plate • Inclined bottom allows infants to easily scoop food from plate surface
- 20. Design Testing • What prototypes were tested? – Plate • Compared to a similar competitor's product (Boon) – Plate holder • What was tested? – Notch Scoopability – Tip Seep – Slide Spill
- 21. Physical Testing Results • Notch • Tip • Slide
- 22. Physical Testing Results • Scoop • Seep • Spill
- 23. Focus Group – Results Develop protocol Discussion guide Post-discussion Recruit mothers Create goals ç ç ç ç ç NovemberOctober December Background • Playtex’s focus groups, also referred to as “Mom groups,” are composed of 15-20 pre-selected mothers Goals • To find out how mothers feel about the implementation of natural materials in mealtime sets • Receive reactions to the plate holder design and how it can be improved
- 24. Focus Group 1 Poll Results Focus Group 2 Poll Results Microwavable Materials Bamboo 1 Mother (8%) Bagasse 12 Mothers (92%) Microwave Dishwasher Serving Bamboo 1 0 3 Bagasse 5 0 3 Cork 0 0 0 PLA 0 0 0 Stainless Steel 0 6 0 Silicone 0 0 0 Microwave Dishwasher Serving Bamboo 0 0 0 Bagasse 6 0 5 Cork 0 0 0 PLA 0 0 3 Stainless Steel 0 4 2 Silicone 0 1 0 Focus Group – Results “It’s really exciting that you’re developing these products – the natural ones” – Mom from Group 1
- 25. Focus Group – Results • 13 out of 13 moms do not heat plastic in the microwave when feeding their children – The mothers like bagasse because it feels natural, is durable, and will not get too hot after heating • When presented with the plate holder, one mother stated “the marriage of materials works” • The most attractive design features were: – bagasse suction of the holder – ease of use disposable option
- 26. Manufacturing PLA Natureworks (Resin Manufacturer) FOB: Blair, Nebraska Cereplast (Resin Distributer and Injection Molding/Thermoforming) FOB: Blair, Nebraska Playtex (Quality Control and Injection Molding or Assembly)
- 27. Manufacturing Sugar Cane Bagasse Brazil Biomass and Renewable Energy Exports S.A. (Bagasse Pellet Manufacturer) FOB: Paranaguá, Brazil BioPlanet (Pulping and Plate/Bowl Pressing) Large Order FOB: Mexico or China Playtex (Quality Control and Assembly)
- 28. Bill of Materials # of Parts Part Title Material Request Build vs Buy Source Labor & Mat CostSpecifications 1 Holder Body Mold Polylactic Acid/Cereplast Hybrid Resins Inner Diameter = 6 in, Out Diameter = 7.5 in, Inner Hole = 1.5 in, Height = 2 in, Inter Lining Perforated every 1/32 in Buy CEREPLAST,INC $1.19 2 Rubber Ring Bottom Rubber Ring Diameter = 6 in. Buy CEREPLAST,INC $0.25 3 Adhesive Resin Amount = 0.5 ounces Buy LHS Enterprises $0.10 4 Bagasse Compartment Plate Insert Bagasse Diameter = 6 in, 3 Check Shaped Cross Section Compartments, Height = .60 in Buy Brazil Biomax $0.26 5 Bagasse Bowl Insert Bagasse Diameter = 6 in, Height = 2.5 in Buy Brazil Biomax $0.24 6 Outer Mold- Fork Polylactic Acid/Cereplast Hybrid Resins Length = 4.5in Buy CEREPLAST,INC $0.33 7 Outer Mold- Spoon Polylactic Acid/Cereplast Hybrid Resins Length = 4.5 in Buy CEREPLAST,INC $0.30 8 Inner Flex Stripe Polyethene Length = 4 in Buy Zhejiang Yulong International Trading Company Ltd $0.25 TOTAL $2.92
- 29. Financials
- 30. Cash Flow Sensitivity to Assumptions -10000 0 10000 20000 30000 40000 50000 60000 70000 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Base Case Worst Case Best Case
- 31. Financial Forecast Parameters Base Case Net Present Value $12,727,000 Break Even Period 11 Quarters Break Even Amount $622,500 Break Even Units 708,750 IRR 81.9%
- 32. Tornado Diagram ($10,000.00) ($5,000.00) $0.00 $5,000.00 $10,000.00 $15,000.00 Number of Units Made Per Year Unit Cost Per Unit Sold (in Dollars, from Bill of Materials) Marketing & Support Costs Per Year (People Time, Ads, Travel, Trade Shows, Office Support Net Present Value Under High, Low & Base Assumptions Base Case Best Case Worst Case
- 33. Future Steps – Next Generation Prototype • Changes based on Mom Group • Changes based on new physical testing of desired features • Incorporation of the Playtex prototype into ours – “Mom Group” of next generation prototype • Design updated based on final results • Large number of participants (~100) • Smaller group sizes per session – Marketing Strategy Development • Emphasize “green” product • Emphasize ease of use and safety – Manufacturing Ramp up • Employ suggested foreign producers • Assemble small inventory – Consumer Testing
- 34. Summary
- 35. Acknowledgements • Our company sponsors and customer research team at Playtex – Jeremy Giese – Adriana Kliegman – Cathy Durden – Frank Yang • Our faculty advisors – Prof. Lori Herz – Prof. Todd Watkins • The IPD staff – John Ochs – Lisa Getzler-Linn – Bobbi Spain • Lehigh staff – Devin Tyman – Prof. Richard Vinci – Prof. David Angstadt