Nypro Radius Replenish V8 Edit Matt Notes Pages

Editor's Notes

• #2: Jason
• #3: Speakover: This is the Replenish concept – ultra-concentrated cleaners that consumers purchase in long-life bottles and fill with water from their own taps. Each pod makes 4 refills and each bottle lasts for several years. This reflects a 90% reduction in wasted materials. Follow with first 47 seconds of innovation lab video ending with 1 billion bottles out of landfills.
• #4: Jason
• #5: Jason
• #6: Jason
• #7: Jason
• #8: Jason
• #9: Joe Tokich In speaking about “utility reference product and platform
• #10: Joe Tokich touch on material selection (squeezability, cracking the return valve)
• #11: Joe Tokich touch on material selection In order for the pod to return to its original shape, air must be allowed to enter the pod to “make-up” the space vacated by the liquid, otherwise a vacuum is set up and the pod remains displaced. The air entering the pod must not allow liquid to back flow into the pod. How to accomplish this? Of the methods available, the fastest to commercialization was the Radius invented, designed and optimized twin-valve system.
• #12: Joe Tokich While there were a number of challenges in the design of the Replenish Reusable Bottling System, we are highlighting one key technical challenge in this presentation. In order for the product to “work”, all of the following have to happen flawlessly: User squeeze force must be low enough and flow rate high enough so as not to induce fatigue for the user; once the single ounce is dispensed, the pod must return to its original shape; and when the bottle is filled, the fluid must not leak back into the pod and additional concentrate must not flow into the bottle. In order for the system to work and to be used, gas tight and fluid tight seals must be established. We examined a number of options that were limited due to the form factor of the system and landed on ultrasonic welding. Other options included solvent bonding, UV curing adhesives, IR welding, and RF welding. U/S was chosen for three primary reasons: Nearest in technology, most familiar to manufacturing personnel, most likely to be successful. The key challenges were related to both material selection (PET was our lead material choice for a number of reasons, but it isn’t exactly U/S welding friendly) and engineering the welding system to create a near-field weld condition rather than a far-field weld condition. The selected valves have some limitations that we needed to understand and design around. The primary concern was the inevitable knit line that would be created where flow fronts meet as material flows around the valve stem coreout in the tool. These knit lines would create surface discontinuities that would create leak paths for the fluids and had to be minimized to the extent practicable.
• #13: The headline material news over the past year of has been bio-derived plastics. 30%. 100%. Derived from corn, sugar, husks… Before this compostable plastics grabbed the lion’s share of news and of course recycling has been with us for decades. With the wide variety of package types, usage situations and fit ness for use requirements, there may never be a one-size fits all sustainabiltiy solution for packaging. What is for certain though is the perpetual need for collaboration and innovation in order to continually drive the balance of cost, performance, and lessened environmental impact to a more favorable state. Consumers and brands will demand it and our industry’s creative abilities will be tested by it. So where does the raw material company fit in with the collaboration required to produce ever more creative and impactful results? For Eastman, our contributions typically begin when a brand or designer or part manufacturer recognizes a need for producing a clear, tough, chemically resistant part with other specialized performance requirements. When those specialized requirements involve sustainability issues, Eastman has a range of materials to address the combination of choices that brands make. (Use hand gesture to count ‘four’ and show ‘three’) Materials that enable re-usability like these Replenish and sport bottles. Materials that enable recycling Materials that enable blow molded handle ware for gripping without the weight or breakage risk of glass Materials for food and beverage re-use such as the Camelback bottle made from Eastman’s new Tritan copolyester that enable dishwasher durability The requirements for Replenish called for materials that enabled the first four choices.
• #14: The chemistry and technology behind Eastman’s copolyester family allows us to offer a range of products to suit a range of requirements. These materials offer identical end-use appearance while enabling process-abiltiy on virtually every molding system: from extrusion, injection molding, injection blow molding, injection-stretch blow molding even reciprocating head and wheel blow molding systems. This translates to design and production freedom that is exemplified by the Replenish technology. In addition to the sustainable elements other requirements of the Replenish package addressed in their material selection included clarity, mold flow capabiltiy, sonic welding requirements, & squeezability. Eastman copolyesters EB062 (for the pod) and EN067 (for the upper portion of the package) were selected due to their specific balance of required attritbutes. The material’s durability supports the multi-year value proposition at the consumer level as well as at the level of manufacturing, assembly, filling, shipping, and storage. Replenish’s choice of emphasing recyclabiltiy of bottle and pod also supported the choice of these materials. The squeezabiltiy of the pod and the need for it to return to shape rapidly was enabled by EB062’s lower modulus than is found in traditional extrusion grade PET resins. EN067’s low molecular weight relative to traditional extrusion grade PET resins accommodated the required mold flow of the Replenish design’s upper part tooling. EN067’s ability to limit crystalization at high temperatures in the injection molding process relative to other extrusion grade PET’s allowed for the desired thickness and clarity throughout the entire part even at the tricky areas of the gate, neck and weld points. Bothe of these characteristics of EN067 helped enable “packaging the mechanics in an elegant manner” as Joe phrased it which is such an important part of this product’s charm to the consumer. Clarity throughout the entire part conveys a purity that the consumer can relate with the desired pristine-clean state of their home. (My wife and I have three boys under 10 years old at home and I do my fair share of cleaning so I know what I’m talking about when I say that those 1 or 2 minutes when the house is clean are very gratifying to me. (haha) I see that potential for my home when I see this package. A household cleaner bottle that looks and stays clean over the lifetime of the product – especially a lifetime as long as Replenish’s sends a powerful message. The unique balance of these characteristics is what Eastman’s copolyesters brought to this collaboration. The materials enhanced consumer experience and increased its value throughout the value chain. Joe has some additional thoughts on the subject of the value chain downstream of design and materials and molding,.
• #17: Eastman’s Innovation Lab is a site where the advancement of design through materials is celebrated and encouraged. Technology adoption begins with innovating benefits and ends with mass market acceptance of those benefits. In between is the adoption gap. Eastman’s Innovation Lab seeks to connect and inspire innovators…. designers, manufacturers, entrepreneurs, students, material suppliers, and brands to collaborate around innovation and the acceleration of bridging adoption gaps. The innovation lab does this through words, pictures, and videos that celebrate the genius of innovative products… It tells the story behind the products in a way that can inspire more innovation And it ties those products and stories to the materials and technology that enabled them and will enable future innovations. If you’ve enjoyed this presentation today and want further inspiration on the value of collaboration, then I invite you to explore the Eastman innovation lab. I’ll ask Jason to wrap things up before our Q&A with some concluding thoughts.
• #18: The Replenish project which we were all a part of exemplifies positive outcomes that can emerge at the intersection of circular integrated engagement and innovative materials. For those of you who are unfamiliar with Replenish, we want to share a video from the Eastman Innovation lab where you can find a trove of inspiration around materials, design thinking, and collaboration.
• #20: Jason