Final Presentation - reNUKable

Understanding Life Anna Troutt, Junsik Kong, Olivia Molloy, Rohan Sarathy

OUR CHALLENGE MUST HAVES

Plastic free packaging Exposed and visible product Able to be merchandised (peg or shelf) ISTA 3A compliant Pack out instructions included

LIKE TO HAVES

Designed for automation

DISTRIBUTION

Shipped on 48”x40” US GMA pallet (2 high in trailer) Designed to be sold to Walmart, Target, Buy Buy Baby

MANUFACTURING

Packed out in WI Facility - initially hand packed → automated Ergonomic with simplification of pack out Intuitive design for easy product placement

TARGET MARKET

Walmart, Target, Buy Buy Baby Parents of newborns and toddlers

Note: Each product tested in a master case containing 12 products

CURRENT DESIGNS all of the current designs rely on the use of some, if not entirely, plastic

Paperboard

HDPE

PET

Paperboard

PET

Comfy™ PACIFIERS

LARGE LEARNER

HARD SPOUT

Recreate the primary packaging of the proposed product line to: Appeal to mothers and fathers alike by providing them sustainable, recyclable packaging while creating a cohesive line that promotes the purchase of NUK products throughout a child's development.

Meet . . .

100% paperboard designs highlighting product visibility and maintaining security

Box is angled so front and the sides can be viewed at once Can be hung on a peg

Insert allows for easy access during unboxing experience Packaging highlights unique features of the NUK product

Exposed product

Smaller window allows for the products security in the box Can sit on a shelf

3 PK PACIFIER PACK OUT PRIMARY

SHIPPER

1.

2.

3.

4.

5.

6.

7.

8.

1.

2.

3.

4.

5.

Remove cutouts Crease all folds Adhere the glue-tab Fold over hang placard Close bottom flap Add pacifiers to insert Fit insert into the box Close top flap

6.

7.

Crease all folds Apply glue to glue tab Square shipper sides Close bottom flap and tape Add 4 primary packages to inner bags - add 3 bags per shipper Close and tape top flap Tape top flaps in I pattern

PACIFIER TESTING SET-UP Required ISTA 3A: Small ● Top load (80lbs) ● Vibration test performed via small standard for small packaged products due to external dimensions ● Shipper tested in a bag full of dunnage ○ Top load placed on top (in another bag) In bag vibration testing for small packages ● Face 1 for 30 minutes ● Face 2 for 30 minutes In bag drop test for small package ● 6 drop sequences alternating between faces 2, 3, 6 at 24in.

PACIFIER TESTING RESULTS Results ● Compression stress to box faces ● Corners crushed due to compression and drops ● No damage done to product, slight superficial damage done to shipper ○ Slight bending of primary packaging hang tabs (remedied when product is hung on peg) ○ All product remained in the packaging throughout the entirety of ISTA-3A Challenges ● Pacifier shipper was 3A standard but is designated as a “small package” due to its external dimensions ● Requires testing in a bag full of dunnage with top load on top in another bag ● Shipper survived a more rigorous test with topload plates rather than a dunnage bag

VIBRATION AND DROP TEST RESULTS

Despite slight damages on the shipper due to drops and vibration testing, there were no damage to the primary packaging inside.

Can be hung on a peg Handles fit into packaging so that it cannot be removed without full disassembly

Holes for the handles

Packaging optimized so that the least amount of board is used Packaging does not need to be glued, design features tabs Similar iconography for better continuity and brand recognition

100% Paper

Can sit on a shelf

LARGE LEARNER PACK OUT PRIMARY

SHIPPER

1.

2.

3.

1.

2.

3.

4.

4.

5.

6.

7.

Remove cutouts Crease all folds Attach placard to bottle mouth Attach handle and screw on bottle top Fold hang placard Insert arm tabs into hang placard holes Adjust for straightness

5.

6.

Crease all folds Apply glue to glue tab Square shipper sides Close bottom flap and tape in I-pattern Add primary packages with arms nestled Close and tape top flap in H-pattern

Top of the bottle is captured without sacrificing mouthpiece visibility Bottle is able to sit on shelf and packaging takes minimal space Packaging does not need to be glued, design features tabs Similar iconography to pacifier and learner for better continuity and brand recognition

Can be hung on a peg

100% Paper

Can sit on a shelf

HARD SPOUT PACK OUT PRIMARY 1.

2.

3.

4.

5.

6.

7.

Remove cutouts Crease all folds Attach placard to bottle mouth Screw on bottle top Fold hang placard Insert arm tabs to hang placard holes Adjust for straightness

SHIPPER 1.

2.

3.

4.

5.

6.

7.

8.

Crease all folds on box and inner, set inner aside Apply glue to glue tab Pop shipper up Close bottom flap and tape Insert corrugated inner Add primary packages to shipper in insert Close and tape top flap Tape shipper in H pattern

HARD SPOUT AND LARGE LEARNER TESTING Both shippers tested to ISTA 3A Standard Drop Sequence 1 ● 8 drops at 18 inches ● 1 drops at 36 inches Vibration testing Top load calculated in accordance to outside dimension ● 1 hour on face 3 ● 30 minutes (each) face 4 and 6 ● 30 minutes face 3 - no topload Drop Sequence 2 ● 7 drops at 18 inches ● 1 drops at 36 inches ● 1 drops at 18 inches with hazard block

RESULTS OF HARD SPOUT AND LEARNER BOTTLE TESTING Because of damage criteria, we determined that the creasing and folding that occurred to the packaging was not deemed a failure and this did not require a second round of ISTA 3a testing. Only damage that occurred was to packaging and not product Issue: ● Bottle closure screwed on too tight ● Teeth diameter is too small which causes pressure and friction Result: ● Minor warping/bending of the primary packaging ● Packaging support on the sides of the bottle snaps Solution: ● Adjusting the dimensions of the teeth (diameter of circle) ● Ensuring the cap is not screwed on too tight

NECESSITY OF TRAYS IN HARD SPOUT SHIPPER

Hard spout 1st testing without tray

E-Flute Corrugated Tray

Hard spout 2nd testing with tray

Because of hard spout bottle geometry, specifically when the bottle is captured from the top, the bottle can rotate and nestle under each other. This resulted in significant damage during testing. To pass testing, we have created an insert. This can be a point of optimization in the future.

Newell Brands Sustainability Goals and Commitment: Commitment to achieve carbon neutrality by 2040 for all Scope 1 and 2 emissions and 90 percent waste to landfill reduction by 2025

SUSTAINABILITY sustainability analysis from from all 3 perspectives of the life-cycle

Upstream -

Embodied Carbon Embodied Energy Material Requirement % Recycled vs Virgin Material Inputs

Distribution & Use

Downstream

- Light-Weighting - Transportation Emissions

- Recyclable vs Recycled - Cost of Non-Recyclable

SUSTAINABILITY upstream perspective: embodied carbon and embodied energy for each design (scope 2) Embodied Carbon (kgCO2-eq./kg): the CO2 emissions from the sourcing and processing of a raw material

Embodied Energy (kWh/kg or MJ/kg): the sum of all the energy needed in producing the material

Embodied Carbon and Embodied Energy per kg by Material:

Actual Embodied Carbon Emissions and Embodied Energy per Unit:

Plastics Materials

Embodied Carbon kgCO2-eq./kg 2.54

54.4 MJ/kg Feedstock Energy (Included).

High Density Polyethylene (HDPE) Resin

1.93

54.3 MJ/kg Feedstock Energy (Included). Doesn’t include the final fabrication.

Paper

Paperboard (General for construction use)

Embodied Carbon kgCO2-eq./kg

1.29 CO 2 Only

Material Use per unit (g)

Actual Embodied Carbon Emissions (kgCO 2-eq./unit)

Actual Embodied Energy (MJ/unit)

Original

PET: 4.15 Paperboard: 5.35

0.0174

0.2258

New

Paperboard: 25.96

0.0335

0.000

Large Learner Cup

Original

HDPE: 3.84

0.0074

0.2085

New

Paperboard: 7.05

0.0101

0.000

Hard Spout Cup

Original

PET: 8.06 Paperboard: 5.75

0.0316

0.7507

New

Paperboard: 7.80

0.0091

0.000

Comments

General Polyethylene

Materials

Design

Product

Comfy™ Pacifiers

Comments Excluding calorific value (CV) of wood, excludes carbon sequestration/biogenic carbon storage.

Source: Inventory of Carbon & Energy (ICE Model), Bath University

SUSTAINABILITY distribution & use perspective: transportation carbon emissions for each design (scope 1) Kilograms of CO 2 emitted per metric ton of freight and per km:

Transport Type

CO 2 emission (kgCO 2-eq.)

Airplane (air cargo), avg Cargo B747

0.500

Modern truck

0.060 to 0.150

Modern train

0.030 to .100

Modern ship (sea freight)

0.010 to 0.040

Source: https://timeforchange.org/

Assumptions:

Transportation Emissions in kgCO

Product

Comfy™ Pacifiers

Large Learner Cup

All NUK products are made in the USA Hard Spout Cup

-eq. per 1 thousand units of 161 km truck transit:

Material Use per unit (g)

Total Weight per unit (g)

Transportation Emissions (kgCO 2-eq./unit)

Original

PET: 4.15 Paperboard: 5.35

9.50

229.42

New

Paperboard: 25.96

25.96

626.93

Original

HDPE: 3.84

3.84

92.74

New

Paperboard: 7.05

7.05

170.26

Original

PET: 8.06 Paperboard: 5.75

13.81

333.51

New

Paperboard: 7.80

7.80

188.37

Design

-

Assume modern truck transportation and maximum emissions, 0.150 kgCO 2-eq.

According to U.S. Dept. of Transportation, 2020: 30% of truck freight trips are <100 miles Use max of 100 miles, or 161 km , for transportation distance

2

SUSTAINABILITY summary of total life cycle impact for each design

Design

Material Use Per Unit (g/unit)

Actual Embodied Emissions (kgCO 2-eq./unit)

Actual Embodied Energy (MJ/unit)

Truck Transportation Emissions (kgCO 2-eq./ 1k units over 161 km)

Downstream Recyclability

Original

PET: 4.15 Paperboard: 5.35

0.0174

0.2258

229.42

Materials Recycled Separately

New

Paperboard: 25.96

0.0335

0.000

626.93

100% Recyclable

Large Learner Cup

Original

HDPE: 3.84

0.0074

0.2085

92.74

Municipality Dependent

New

Paperboard: 7.05

0.0101

0.000

170.26

100% Recyclable

Hard Spout Cup

Original

PET: 8.06 Paperboard: 5.75

0.0316

0.7507

333.51

NOT Recyclable

New

Paperboard: 7.80

0.0091

0.000

188.37

100% Recyclable

Product

Comfy™ Pacifiers

PROJECT GOALS achieved the must haves for all three products

Plastic free, sustainable Exposed and visible product Able to be merchandised ISTA 3A compliant Pack out instructions given

FUTURE RECOMMENDATIONS Remove inner packaging - to eliminate all plastics and unnecessary corrugated weight Add paper stickers for tamper evidence

Experiment with glue tabs to aid automation in pack out.

Sacrifice pacifier visibility to reduce overall carbon emissions and material cost Use recycled material to further reduce environmental impact

QUESTIONS?