Product Design 25% of ChEs work on Products, not Processes

Chapter 1, 2 Article on Product Design CH EN 4253 Terry A. Ring

ChE Education

Chemical Products

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?

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
H2O Salt Soln

Heat Patch/Hand Warmer

4Fe(s) +3 O2Fe2O3 + H
H = -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 eq

Solid

Meta-stable Solid-Liquid Line

Zap Pack
Step1: Activate by flexing 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
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?

Formulated Products
Toothpaste Shampoo Deodorant Mouthwash Dish soap

Active Ingredients
Sodium monofluorophosphate 0.76% Pentasodium triphosphate Tetrasodium pyrophosphate Sodium lauryl sulfate Flavor sodium hydroxide calcium peroxide Sodium saccharin Carrageenan cellulose gum titanium dioxide

Inactive Ingredients
Glycerin Sorbitol Hydrated silica Propylene glycol Sodium bicarbonate Aluminum oxide Water

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

What makes the product desirable?

To whom?

What is the products 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

Other

Ingredients
Commercial Availability Necessary for the Multi-source formulation? Quality What Concentration? Impurities Any difficulty in the Price Quantities Available process?
Packaging

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/)(Co/Kd-0) Kd=Co/Cw =(e Vhand Whand/(2 Papp))1/2 Ficks 1st Law
Distribution Coeff Reynolds Equation

Easy to apply

Lubrication theory

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

Figure of Merit = High Flux, low friction

2 DCo Papp (D/ )(Co / K d ) FM 1/2 ( e Vhand /(2 Papp Whand )) K d e Vhand

FM Values
Formulation Formulation 1 Formulation 2 Formulation 3 FM 0.1 120 2 Cost ($/kg) 20 82 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 date Potential price and sales volume evaluated by marketing department by given date EPA (or other government agency) Registration Build plant to manufacture investment funding, design, construct, debottleneck, run Steps 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
Lost production
cost to produce Rework cost

Costs
Single product Assembled product
Failure per part Total Failure of Assembly
Importance of Failure Shampoo Car Spaceship

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

Develop Product Design

Test Competing Designs Plan Product Manufacture
Quality Assurance Estimate process Variance
determine sigma

Allocate Resources Identify Product Requirements Select Product Concept

Implement Design
Pilot Scale
Verify Manufacturability Verify Quality Verify Profitability

Full Scale

Getting a Product Approved

FDA
Foods Drugs

EPA
Disposal or spill
Waste water Air quality

DOT
Shipping
Spills fires

MSDS

MSDS

Section I. Material Identification:

Chemical Name Copper sulfate penta-hydrate CAS# 7758-99-8 Wt% 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, wellventilated area. Do not freeze. Other Precautions: Keep this product and all other chemicals out of childrens 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