Product Design

25% of ChE’s work on Products,not Processes

Chapter 1, 2Article on Product Design

CH EN 4253Terry A. Ring

ChE Education

Chemical Products

Products Are Everywhere

• But, how are they designed?– Formulated Products– Engineered Products

• Let’s 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?

Engineered Products

• Hemodialysis Device• Hand Warmer

– Fe Powder

• Heat Patch– Fe + C Powders

• Solar Desalination Unit for Home• Zap Pak – Heat Pack• Aroma/Insect Repellant Wall Plugs• Alcohol Fuel Cells

Hemodialysis Device

Hemodialysis

• Counter Current (Shell & Tube HX design) Membrane– Blood– DI Water

• Series of Resistances– Mass Transfer

• Blood• Water

– Diffusion in Membrane• Urea• Byproducts

Home Desalination Unit

• Transparent Cover– Allows Sunlight in– Condenses Vapor

Salt Sol’n

H2O

Heat Patch/Hand Warmer

• 4Fe(s) +3 O2Fe2O3 + ΔH– ΔH = -824.2 kJ/mol

oxide

– Graphite (dilutent+ shelf life)

– NaCl “Catalyst”

– Control Kinetics of Reaction

Zap Pack

• Heat of Crystallization– NaC2H3O2*3H2O -

4.7 kcal/mole

– Na2S2O3*5H2O

-11.4 kcal/mole

– Ca(NO3)2*4H2O -8.0 kcal/mole

Cl

T

eq

Solid-Liquid Line

Meta-stableSolid

Zap Pack

Step1: Activate byflexing metal disc

                                                  

  

Step 2: Liquid crystallizing and heating

 

 

                                                

Step 3: Pad is hot and ready

for use

The clever bit is that the reaction is reversible by just boiling the thing in water

Air Freshener

• Oil mixture• Heated

– Selective Evaporation of oil mixture

– Partial Pressure as a function of Temperature

Direct methanol Fuel Cell

• PEM Fuel Cell– With Special Catalyst

• Anode (oxidation)

Formulated Products

• Let’s 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?

Formulated Products

• Toothpaste

• Shampoo

• Deodorant

• Mouthwash

• Dish soap

Active Ingredients– Sodium monofluorophosphate0.76%

• 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

• Active Ingredients– Sodium fluoride 0.24%

• Inactive Ingredients– Water– Glycerin– Sorbitol– Hydrated silica– Pentasodium

triphosphate– Sodium lauryl sulfate

• Flavor• Tetrasodium

pyrophosphate• PVM/MA copolymer• Sodium hydroxide• Cellulose gum• Sodium saccharin• Carrageenan• Polyethylene• Titanium dioxide• FD&C blue no. 1

• 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

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

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 safe

level. One official and legal version states that a sanitizer must be capable of killing 99.999%, known as a 5 log reduction, of a specific bacterial test population, and to do so within 30 seconds.

• Antiseptics– Antiseptics destroy microorganisms on living tissue.

Deodorant• Active Ingredients

– Aluminum Zirconium Tetrachlorohydrex glycin complex

• Inactive Ingredients– Water– Cyclomethicone– SD alcohol40– Tripropylene glycol– Dimethicon– Propylene Glycol– Phenyl trimethicone– PEG/PPG-18/18– Dimethicone– Fragrance

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

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

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

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

Product Characteristics

• Color• Taste• Smell• Feel

– Rheology

– Surface tension

– Adhesion

• Other

• What makes the product desirable?– To whom?

• What is the product’s competition?

• What makes it better than the competition?

• What makes it profitable?– Price to produce?– Cost of marketing– Profit margins

• Middle men (Sales Reps.)• Retail Outlet

Ingredients

• Commercial Availability• Multi-source• Quality

– Impurities

• Price• Quantities Available

– Packaging

• Necessary for the formulation?

• What Concentration?• Any difficulty in the

process?– Easy to mix– Packaging made easy

• Anti-ageing – Shelf life

Product Description

• Quality Factors

• Use Factors

• Materials Factors

• Process Factors

Chemical Product Pyramid

Figure of Merit

Drug Cream Formulation

Shear force during application

Drug Cream Formulation

• Ingredients– Drug– Oil - dissolves drug– Water– Surfactant to stabilize emulsion– Fragrance– Preservative – keeps bacteria from growing in

formula

Drug Cream Figure of Merit

• Interest Factors– Drug moves from oil in emulsion through water phase

into blood– J=(D/δ)(Co/Kd-0) Fick’s 1st Law

– Kd=Co/Cw Distribution Coeff

– δ=(μe Vhand Whand/(2 Papp))1/2 Reynolds’ Equation

– Easy to apply Lubrication theory– Friction Coefficient = (μe Vhand /(2 Papp Whand))1/2

– Figure of Merit = High Flux, low friction

hande1/2

handapphande

o

V

2

)) WP /(2V (

)/)(C(D/

d

appodM K

PDCKF

FM Values

• Formulation FM Cost ($/kg)

• Formulation 1 0.1 20

• Formulation 2 120 82

• Formulation 3 2 22

Example-1

• Ice Cream– Quality Factors

• Flavor• Creaminess• Smoothness• Coldness

• Flavor controlled by– Ingredients

• Partial Pressure of Flavinoids to Nose

• 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

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

• Volume – how many of different sensors in nose are affected long after opening

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 of Y%

• Meet target with several new refrigerants by given date• New refrigerant must not be corrosive to materials of construction –corrosion tests done

by given date• New refrigerant can be used for a long time with certain polymer seals – lifetime tests

done 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 datePotential price and sales volume evaluated by marketing department by given dateEPA (or other government agency) RegistrationBuild plant to manufacture

investment funding, design, construct, debottleneck, runSteps allow go/no go decisions by management at various Stage Gate Reviews

After a production process is running

• Program of quality control and constant product improvement

• Six Sigma

• ISO-9000

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

6 sigma design

• Define Project (Gantt Chart)– Steps– Time needed

• Allocate Resources• Identify Product

Requirements• Select Product

Concept

• 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

Getting a Product Approved

• FDA– Foods

– Drugs

• DOT– Shipping

• Spills

• fires

– MSDS

• EPA– Disposal or spill

• Waste water

• Air quality

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.

•  

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 in methanol,

glycerol and ethanol.• Appearance: Blue-green liquid.

• Odor: Odorless

Section III. Fire and Explosion Data

• Flash Point: Not applicable•  • Flammability Limits: Not Flammable. If heated and boiled away to

crystals, it can decompose above 400 C and emit toxic copper oxide and sulfur fumes. Above 500 C it emits SO2 fumes.

•  • Extinguishing Media: Does not burn or support combustion. Use

water, CO2 or dry chemicals.•• Special Fire Fighting Instructions: If water is used it will be

contaminated with copper sulfate and care should be taken to be such water out of streams and other bodies of water.

•  • Fire and Explosion Hazards: None

Section IV. Reactivity Data

• Stability: Stable• Conditions to Avoid: Dilution of product into streams or other

bodies of water.•  • Incompatibility: Solution is mildly corrosive to steel. Store

solution 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.

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

upper respiration tract.•  • Carcinogenicity: None as per NTP, OSHA and IARC

Section VI. First Aid Procedures

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

•  • Skin: Wash thoroughly with soap and water. Remove and

wash contaminated clothing before reuse.•  • Eyes: Immediately flush eyes with plenty of water for 15

minutes. Hold eyelids apart during irrigation. Call physician.•  • Inhalation: Remove person to fresh air and call a

physician.•  • Carcinogenicity: None

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 TWA exceeds 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.

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 on reporting

spills. Do not wash away spilled solution. Collect and treat solution by reacting with soda ash to form an insoluble copper carbonate solid that can be scooped up.

•  • Waste Disposal: Comply with Federal, State and local regulations on waste

disposal. React solution with soda ash to form an insoluble copper carbonate solid that 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 concentration is 235 mg/l and plant toxicity is 25 mg/l both expressed as copper sulfate pentahydrate.

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 children’s reach.

Section X. Regulatory Information

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.

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 Preparation Information

Product Innovation Equation

• Innovation = insight + ideas + impact

• Companies are increasingly making innovation part of their culture and corporate strategy.

• Ideas need SUN behavior– Suspend judgment, Understand the idea, Nurture it

along