Proceedings of the 2012 HPC Fall...

Proceedings of the

2012 HPC Fall Meeting

Friday, November 16, 2012

Sabbatini Lounge

Christian Brothers University

650 East Parkway South

Memphis, TN 38104

Table of Contents

Front Cover

Table of Contents

Registered Participants

Program

Abstracts

Packaging Design & Analysis Tools: Translating “Cushion Curve” Data into Packaging Designs with

a Strong Emphasis on “Best Protection” & “Source Reduction” by Matt Thompson

Enhancing Sustainability through Packaging by Jamie Shackelford

Accelerating High Quality Decision Making by Jay Morgan

Sustainable Global Design by Gregory Sedrick and Rita Engler

Healthcare Packaging Consortium & Its Projects (2010 – 2012) by Siripong Malasri, Ray Brown, Asit

Ray, and Larry Rutledge

Effect of High Temperature on Compressive Strength and Impact Acceleration of New Softwood

Pallets by Siripong Malasri, Ali Pourhashemi, Ray Brown, Mallory Harvey, Katie Godwin, Phyo Aung,

James Laney, and Robert Moats

Water Absorption of Wooden Pallets by Siripong Malasri, Ali Pourhashemi, Phyo Aung, Mallory

Harvey, and Robert Moats

Additional Materials

Slides - Accelerating High Quality Decision Making by Jay Morgan

Slides - Sustainable Global Design by Gregory Sedrick and Rita Engler

Paper - Healthcare Packaging Consortium & Its Projects (2010 – 2012) by Siripong Malasri, Ray

Brown, Asit Ray, and Larry Rutledge

Paper - Effect of High Temperature on Compressive Strength and Impact Acceleration of New

Softwood Pallets by Siripong Malasri, Ali Pourhashemi, Ray Brown, Mallory Harvey, Katie Godwin,

Phyo Aung, James Laney, and Robert Moats

Slides - Water Absorption of Wooden Pallets by Siripong Malasri, Ali Pourhashemi, Phyo Aung,

Mallory Harvey, and Robert Moats

Back Cover

Members

Evergreen Packaging, FedEx, Medtronic, Merck Consumer Care

Plastic Ingenuity, Smith & Nephew, The Pallet Factory, Wright Medical

Registered Participants

1. Aflaki, James Christian Brothers University

2. Ahleman, Jason Merck

3. Aung, Phyo Christian Brothers University

4. Baker, Chad Christian Brothers University

5. Brown, Ray Christian Brothers University

6. Buckingham, Shronda International Paper

7. Choudhary, Divya Christian Brothers University

8. Garcia, Luis Christian Brothers University

9. Godwin, Katie Christian Brothers University

10. Graham, Heidi Merck

11. Haddon, Jim Merck

12. Head, Benjamin Christian Brothers University

13. Harvey, Mallory Christian Brothers University

14. Jenkins, Joseph Olympus Surgical Technologies

15. Jordan, Rhett Christian Brothers University

16. Kneipp, Wayne International Paper

17. Laney, James Christian Brothers University

18. Malasri, Pong Christian Brothers University

19. Moats, Robert Christian Brothers University

20. Morgan, Jay Merck

21. Phaneuf, Robert Wright Medical

22. Pourhashemi, Ali Christian Brothers University

23. Qvyjt, Fernando Evergreen Packaging

24. Ray, Asit Christian Brothers University

25. Rutledge, Larry Christian Brothers University

26. Sampson, Nathan Christian Brothers University

27. Scamardo, Joseph Olympus Surgical Technologies

28. Sedrick, Greg Christian Brothers University

29. Shackelford, Jamie Sealed Air Corporation

30. Shiue, Paul Christian Brothers University

31. Simpson, Melissa Merck

32. Siow, Wei Christian Brothers University

33. Stevens, Ryne Christian Brothers University

34. Thompson, Matt Sealed Air Corporation

35. Topinka, Matt Merck

36. Tune, Mike Merck

37. Ventura, John Christian Brothers University

38. Witteborg, Norman Wright Medical

Members

Evergreen Packaging, FedEx, Medtronic, Merck Consumer Care

Plastic Ingenuity, Smith & Nephew, The Pallet Factory, Wright Medical

2012 HPC Fall Meeting Friday, November 16, 2012

Sabbatini Lounge, 2nd

Floor of Thomas Center, Christian Brothers University

650 East Parkway South, Memphis, TN 38104

8:00 a.m. – 8:45 a.m. Check-in/Continental Breakfast

Poster Session

8:45 a.m. – 10:15 a.m. Packaging Design & Analysis Tools: Translating “Cushioning Curve” Data Into

Packaging Designs with a Strong Emphasis on “Best Protection” & “Source

Reduction”

Matt Thompson, Director of Packaging and Technical Services

Sealed Air Corporation

10:15 a.m. – 10:30 a.m. Coffee Break

10:30 a.m. – 12:00 noon “Enhancing Sustainability through Packaging”

Jamie Shackelford, Product Line Manager, Special Foams

Sealed Air Corporation

12:00 noon – 1:00 p.m. Lunch

Keynote Address: Accelerating High Quality Decision Making

Jay Morgan, VP of R&D Operations

Merck

1:00 p.m. – 1:15 p.m. Break

1:15 p.m. – 2:45 p.m. “Sustainable Global Design”

Gregory Sedrick, Graduate Engineering Director

Christian Brothers University

2:45 p.m. – 3:00 p.m. Coffee Break

3:00 p.m. – 4:30 p.m. Healthcare Packaging Consortium & Its Projects (2010-2012)

Siripong Malasri, Ray Brown, Asit Ray, and Larry Rutledge

Healthcare Packaging Consortium, Christian Brothers University

Effect of High Temperature to Compressive Strength and Impact Acceleration

of New Softwood Pallets

Siripong Malasri, Ali Pourhashemi, Ray Brown, Mallory Harvey, Katie Godwin,

Phyo Aung, James Laney, and Robert Moats


Water Absorption of Wooden Pallets

Siripong Malasri, Ali Pourhashemi, Phyo Aung, Mallory Harvey, and Robert Moats


Campus Map: http://www.cbu.edu/about/campusmap.html

Sponsors:

Sealed Air Corporation, Merck, CBU Graduate Engineering

http://www.cbu.edu/about/campusmap.html

http://www.sealedair.com/default.aspx

http://www.merck.com/index.html

http://www.cbu.edu/engineering/home.html

ABSTRACTS

2012 HPC Fall Meeting, November 16, 2012, Memphis, Tennessee, USA

Packaging Design & Analysis Tools: Translating “Cushioning

Curve” Data into Packaging Designs with a Strong Emphasis on

“Best Protection” & “Source Reduction” Matt Thompson

1

Abstract: In the lab and in the field, it’s critical to have a strong understanding of cushioning materials and how

their performance relates to good packaging design. This presentation will demonstrate some new transmitted shock

and packaging design analysis tools to quickly translate “cushioning curve” data into designs with a strong emphasis

on “best protection” and “source reduction”.

Keywords: Packaging design, cushioning materials, cushioning curve, transmitted shock, source reduction, product

protection, packaging engineering

Author:

Matt Thompson – Mr. Thompson is Director of Packaging and Technical Services of Sealed Air Corporation. With

over 20 years of experience at Sealed Air working in packaging engineering, laboratory management, marketing,

product and technical development, Matt is responsible for a world-wide network of 30 packaging design &

development centers. He has a BS degree in Packaging from San Jose State University in California.

1 Sealed Air Corporation, 10 Old Sherman Turnpike, Danbury, CT 06810,

[email protected]


Enhancing Sustainability through Packaging

Jamie Shackelford1

Abstract: Government, customers, smart investors and consumers see the economic as well as environmental sense

in being environmentally responsible. We will focus on understanding the Federal Trade Commission guidelines

and how they apply to packaging. Compliance in the industry, certifications of products and processes and new

offerings are driving the industry forward to improved sustainability through packaging.

Keywords: Packaging, sustainability, Federal Trade Commission

Author:

Jamie Shackelford – Jamie Shackelford is a Global Product Line Manager for Sealed Air Corporation. Mrs.

Shackelford manages a variety of differentiated foam products that service the cushioning and low abrasion

packaging markets.

1 Sealed Air Corporation, 2401 Dillard Street, Grand Prairie, TX 75051,

[email protected]

mailto:[email protected]


Accelerating High Quality Decision Making Jay Morgan

1

Abstract: HealthCare businesses have always been extremely competitive, but recent macroeconomic changes have

transformed the way we do business.

Supply chains are increasingly complex, requiring many separate organizations to work seamlessly together

to design, develop and manufacture products

Technology and globalization have increased competition, causing ever increasing pressures on

development time and acceleration of the pace of innovation. Organizations must be more adaptive to

change than at any time in their history.

Consumers and customers alike are demanding customization.

Governmental and customer regulations are becoming more demanding and more comprehensive.

"Business as usual" will not allow us to rapidly adapt to a very fluid global environment. Technology - e-mails,

video-conferencing, and phone calls - will always have their place in the business world. Real time communication

in a dynamic environment, however, is the key to the acceleration of rapid, high-quality decision making.

Mr. Morgan will discuss the challenges and opportunities associated with transitioning an entrenched "business as

usual" culture into an open and collaborative environment.

Keywords: Decision making, global environment, collaborative environment

Author:

Jay Morgan - Jay Morgan is Vice President Research & Development, Chief Operating Officer Research Operations

for Merck Consumer Care. He is accountable for driving growth through innovative product development of

Merck's OTC Drug, Device and Cosmetic products. His breadth of experience includes leadership of global product

development, R&D Support Services, Portfolio Management, R&D Resource Allocation, R&D IT Systems for both

OTC Drug and Cosmetic organizations. Prior to joining Merck, Jay led product development teams for several

leading consumer companies such as Maybelline, Bath & Body Works, and Victoria's Secret prior to joining Merck

Consumer Care in 2001. Jay currently manages development for all Merck Consumer Brands including Claritin,

Afrin, Coppertone, Dr. Scholl's, Miralax, Lotrimin, Tinactin and Coricidin. Mr. Morgan also has experience in

evaluating local emerging market R&D operations to optimize performance in countries such as Brazil, China,

Russia and Mexico. In addition to R&D Operations, Mr. Morgan has been focusing on transforming MCC's

innovation approach to a more consumer empathetic, iterative and prototype driven approach (Design Thinking).

This transformation requires creating a deep relationship with the consumer as well as creating a diverse ultra-

collaborative internal environment.

1 Merck, 3030 Jackson Avenue, Memphis, TN 38151, [email protected]


Sustainable Global Design

Gregory Sedrick1and Rita Engler

2

Abstract: This session is based upon the facilitator’s travel in the past twelve months to 10 European, 4 South

American, two Mexican, two Canadian, and twelve US cities in search of answering the research question “How can

we design products and services that are globally sustainable?”

Product and service design, including packaging, for a global market requires a philosophical model to follow, an

infrastructure to support and adjustments for cultural differences. Simply put, a sustainable design vision is needed

but with a bias toward a Monday morning action plan.

Doing business in a flat world, successful global design with a world of global team members, requires collaboration

regardless of location, organizational unit or job role. It requires adjusting the model for cultural barriers and local

usage. The great world recession (2008-2011) has complicated this strategy with never before seen stresses on faster

responses conducted more efficiently. It requires understanding the Masters, avoiding both the quick fix and buzz

word application while staying current on the latest technology.

This interactive session covers the considerations for Sustainable Global Design of products, services and obviously

packaging. The session leader will facilitate “exercises” to bring validity to his presentation for later implementation

at the participant’s organization. It covers both models and immediate guides to action.

Keywords: Sustainable global design

Authors:

Gregory Sedrick - Dr. Sedrick, P.E. is Professor and Director of Graduate Engineering at Christian Brothers

University. He previously served in various academic and administrative positions at the University of Tennessee,

UT Space Institute, LaTourneau University, Chattanooga State Technical Community College, University of

Tennessee at Chattanooga, Virginia Tech, and the Army Management Engineering College. He also served as State

Executive Director of the Tennessee Small Business Development Center (TSBDC) Network, which provides

existing and pre-venture small business owners with counseling and training. Dr. Sedrick was Founder and

Executive Director of the New Economy Institute, which was established to assist businesses in the application of

new technology and workforce development in the seven congressional districts of the Tennessee Valley Technology

Corridor.

Rita Engler - Dr. Engler is Professor of Innovation and Sustainability Graduate Design Program at Universidade do

Estado de Minas Gerais, Brazil. She co-chairs the NEI International Consortium on Graduate Education.

1 Christian Brothers University, 650 East Parkway South, Memphis, TN 38104,

[email protected]

2 Universidade do Estado de Minas Gerais, Brazil


Healthcare Packaging Consortium & Its Projects (2010 - 2012)

Siripong Malasri1, Ray Brown

2, Asit Ray

3, and Larry Rutledge

4

Abstract: The Healthcare Packaging Consortium was founded at Christian Brothers University (Memphis,

Tennessee, USA) in 2010. Currently, there are eight companies that are members, namely Evergreen Packaging,

FedEx, Medtronic, Merck, Plastic Ingenuity, Smith & Nephew, The Pallet Factory, and Wright Medical. Its mission

is to advance healthcare packaging knowledge through research and education. The consortium research work is

supported by the CBU ISTA’s certified package testing commercial lab. This paper gives an overview of the

consortium and its R&D projects during June 2010 to May 2012, including plastic tote distribution, water absorption

of wooden pallets, correlation of peel and burst testing of pouches, peel testing analysis, and performance of recycled

corrugated boards/boxes.

Keywords: Healthcare packaging, plastic totes, wooden pallets, peel test, burst test, recycled corrugated

boards/boxes

Authors:

Siripong Malasri – Dr. Malasri is Professor of Civil Engineering at CBU, where he also serves as Packaging Department Chair and Healthcare

Packaging Consortium Coordinator. He obtained his Ph.D. from Texas A&M University and is a registered professional engineer in Tennessee.

Dr. Malasri was instrumental to the establishment of the packaging engineering program at CBU during his term as engineering dean from 1999-

2005. His background includes construction management, structural engineering, solid mechanics, materials testing, artificial intelligence,

optimization, and packaging. He is a member of IoPP, TAPPI, and NSPE.

Ray Brown – Dr. Brown is Professor Emeritus of Mechanical Engineering at Christian Brothers University. He earned his Ph.D. from the

University of Notre Dame. He has also served as mechanical engineering department chair and engineering dean at CBU. His interests include

mechanical and thermal systems. He is a member of ASME.

Asit Ray – Dr. Ray is Professor of Chemical Engineering at CBU. He earned his Ph.D. from Lehigh University. He spent seven years in the

polymer industry and is actively engaged in laboratory research in polymeric and biomaterials. He teaches various packaging classes at CBU,

including principles of packaging, distribution and medical device packaging, and sustainability. He is a member of IoPP and AIChE.

Larry Rutledge – Mr. Rutledge is retired from FedEx where he managed FedEx Packaging Design and Development department for over 18

years. Larry earned his B.S. in Engineering Technology from Memphis State University and M.S. in Technical Education from University of

Memphis. Larry has a diverse background in mechanical systems design, facility planning, industrial engineering, project management, package

testing and design and logistics solutions. Larry is past Chairman of the IoPP Transport Packaging Committee, Board of Directors for ISTA, and

Board of Director for Michigan State University Consortium on Distribution Packaging. Larry is continuing his Packaging Career as a

consultant. He also serves as Manager with CBU's ISTA Certified Lab.

1, 2, 3, 4 Healthcare Packaging Consortium, Christian Brothers University, 650 East Parkway

South, Memphis, TN 38104, [email protected], [email protected], [email protected], and [email protected].






Effect of High Temperature on Compressive Strength and Impact

Acceleration of New Softwood Pallets

Siripong Malasri1, Ali Pourhashemi

2, Ray Brown

3, Mallory Harvey

4,

Katie Godwin5, Phyo Aung

6, James Laney

7, and Robert Moats

8

Abstract: In this study, static compression tests and impact drop tests were performed on new wooden pallet

specimens under temperatures ranging from 80°F to 160°F. As the temperature increases pallet specimens become

weaker, thus compressive strength is lower. This is consistent with the current timber building design practice. The

drop of compressive strength is at a small rate of 0.61 psi per 1°F of temperature increase. When specimens are

weaker, they absorb more impact energy, which results in lower impact acceleration. The drop of impact

acceleration is also at a small rate of 0.034g per 1°F of temperature increase.

Keywords: High temperature, compressive strength, impact property, softwood pallets

Authors:

Siripong Malasri – Dr. Malasri is Professor of Civil Engineering at Christian Brothers University, where he also serves as the Packaging

Department Chair and Healthcare Packaging Consortium Coordinator. He obtained his Ph.D. from Texas A&M University and is a registered

professional engineer in Tennessee. Dr. Malasri was instrumental to the establishment of the packaging engineering program at CBU during his

term as engineering dean from 1999-2005. His background includes construction management, structural engineering, solid mechanics,

materials testing, artificial intelligence, optimization, and packaging. He is a member of IoPP, TAPPI, and NSPE.

Ali Pourhashemi – Dr. Pourhashemi is Professor of Chemical Engineering at CBU. He earned his Ph.D. from the University of Maryland at

College Park. He has authored and co-authored various publications in the areas of fluid mechanics, heat/mass transfer, and instrumentation. Dr.

Pourhashemi is a member of the American Institute of Chemical Engineers.

Ray Brown – Dr. Brown is Professor Emeritus of Mechanical Engineering at Christian Brothers University. He earned his Ph.D. from the

University of Notre Dame. He has also served as mechanical engineering department chair and engineering dean at CBU. His interests include

mechanical and thermal systems. He is a member of ASME.

Phyo Aung, Mallory Harvey, and James Laney – Ms. Aung , Ms. Harvey, and Mr. Laney are civil engineering majors with a packaging minor at

Christian Brothers University. Their interests include structural engineering, mechanics, and packaging. They are research assistants in various

Healthcare Packaging Consortium R&D projects.

Katyie Godwin – Ms. Godwin is a recent civil engineering graduate. Her interests include structural engineering, especially timber design.

Currently, she is a research assistant with the Healthcare Packaging Consortium.

Robert Moats – Mr. Moats is a mechanical technician at CBU. He maintains packaging lab equipment and prepares specimens and fixtures for

various Healthcare Packaging Consortium R&D projects.

1,2,3,4,5,6,7,8 Healthcare Packaging Consortium, Christian Brothers University, 650 East

Parkway South, Memphis, TN 38104, [email protected], [email protected], [email protected],

[email protected], [email protected], [email protected], [email protected], and [email protected]











Siripong Malasri1, Ali Pourhashemi

2, Phyo Aung

3, Mallory Harvey

4, and Robert Moats

5

Abstract: Wooden pallets are often left outdoors and subjected to rainwater. Water can seep upward and damage

the packages stored on these pallets. A comprehensive study was performed using a total of 36 specimens taken

from hardwood, heat-treated hardwood, softwood, and heat-treated softwood new pallets. Another four specimens,

taken from softwood used pallets, were also used to compare with new pallet specimens. Findings include: water

penetration height could penetrate up to the top deck board, water penetration data is more consistent in hardwood

than in softwood, water penetrates faster and slightly higher in hardwood, heat treatment has only a little effect on

water penetration, and little difference is found in used and new pallet specimens.

Keywords: Wooden pallets; water absorption

Authors:

Siripong Malasri – Dr. Malasri is Professor of Civil Engineering at Christian Brothers University, where he also

serves as the Packaging Department Chair and Healthcare Packaging Consortium Coordinator. He obtained his Ph.D.

from Texas A&M University and is a registered professional engineer in Tennessee. Dr. Malasri was instrumental to

the establishment of the packaging engineering program at CBU during his term as engineering dean from 1999-

2005. His background includes construction management, structural engineering, solid mechanics, materials testing,

artificial intelligence, optimization, and packaging. He is a member of IoPP, TAPPI, and NSPE.

Ali Pourhashemi – Dr. Pourhashemi is Professor of Chemical Engineering at CBU. He earned his Ph.D. from the

University of Maryland at College Park. He has authored and co-authored various publications in the areas of fluid

mechanics, heat/mass transfer, and instrumentation. Dr. Pourhashemi is a member of the American Institute of

Chemical Engineers.

Phyo Aung and Mallory Harvey – Ms. Aung and Ms. Harvey are civil engineering majors with a packaging minor at

Christian Brothers University. Their interests include structural engineering, mechanics, and packaging. Both are

research assistants in various Healthcare Packaging Consortium R&D projects.

Robert Moats – Mr. Moats is a mechanical technician at CBU. He maintains packaging lab equipment and prepares

specimens and fixtures for various Healthcare Packaging Consortium R&D projects.

(Note: The manuscript of this presentation will be published in International Journal of Applied

Science and Technology, Vol. 2, No. 8, December 15, 2012.)

1, 2, 3, 4, 5 Healthcare Packaging Consortium, Christian Brothers University, 650 East Parkway

South, Memphis, TN38104, [email protected], [email protected], [email protected], [email protected],

and [email protected]






ADDITIONAL

MATERIALS

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Accelerating High Quality Decision Making

Setting the Stage for Improving Execution & Innovation

Jay MorganVP R&D, Chief Operating Officer Research Operations

Merck Consumer [email protected]

Accelerating High Quality Decision Making

Setting the Stage for Improving Execution & Innovation

Road Map for Today’s Conversation

• Increased collaboration drives speed, decision quality & ownership

• Relationship of collaboration models and innovation type

• Setting the workplace stage to enhance a collaborative culture.

• What type of results can I expect?

• Coming to your neighborhood

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Even if “business as usual” is working smoothly……

Will your current operating model enable you to reach your goals?



Wang LaboratoriesEastman KodakBlockbuster

IBMApple

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Bridgette HellerPresident Merck Consumer Care

Merck CC Challenge: More productivity the with same resources

How do the most productive & innovative companies operate?

Innovation Spectrum

Operational Characteristics

Incremental Breakthrough

• Hierarchical• Rigid Lines of Communication• Rarely share unfinished work• Flat Relationships

Operate in “Me” Spaces

• Ultra Collaborative• Free flowing communication• Freely share unfinished work• Multidimensional Relationships

Operate in “We” Spaces

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Me Spaces vs. We Spaces

Consciously or not, we feel and internalize what the space tells us about how to work....Closed‐off desks sprout off of lonely hallways, and in a few obligatory conference rooms a hub table ensure that people are safely separated from one another. Most work spaces were designed according to an industrial labor model, from a time when our work was tethered to big machines and our status was rooted in the size of our office space.

David Kelly, IDEO Founder

Make Space, How to Set the Stage for Creative Collaboration, Doorley & Withoft (foreword)

"We shape our buildings, and afterwards our buildings shape us.“

Winston Churchill 1943

Facebook Unveils New Campus

Facebook just unveiled plans for its new campus expansion. It will be a single room, stretching 10 acres, where everyone will sit in the open with moveable furniture.

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Apple designer describes company's 'kitchen table' in testimonyOn the stand, an Apple designer Christopher Stringer recounts how the company takes a device from brainstorming to market, including sitting around a kitchen table.

…“That’s where the ideas happen,” said Stringer, who started working at Apple in 1995 and is a named inventor on patents for the iPhone and iPad. While Samsung said during the trial that it had more than 1,000 people working on the design of products, Stringer said Apple’s industrial design team is a small group of about 15 people from countries including the U.S., U.K., Australia and Japan.

Breaking with 190 years of tradition, Bloomberg implemented a “bullpen” open office plan, reminiscent of a Wall Street trading floor, in which dozens of aides and managerial staff are seated together in a large chamber. The design is intended to promote accountability and accessibility.

"Walls are barriers, and my job is to remove them“Michael Bloomberg

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When Does It Make Sense to Kill the Cubicle? Forbes May 2012

“There are no cubes, no corner offices and everyone sits together in an open environment,” says Tschudy. “This eliminates ego and hierarchy and encourages teamwork, collaboration, productivity and efficiency.”

Mike Tschudy – VP SAP Cloud Computing

A Prescription for ProfitAn open‐plan office at GSK leads to massive productivity gains and $50 million in revenue growth—from just one product line.

In GlaxoSmithKline’s innovation hubs, scientists and salespeople work together in open spaces that encourage collaboration—and have led to dramatic productivity increases

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A Personal Moment Between Two Individuals…..

In a 1999 Harvard Business Review article entitled "The Human Moment at Work," psychiatrist Edward Hallowell points out that the anxiety many people feel at work has a simple antidote: a personal moment between two individuals in the same place at the same time. This encounter might take only a few minutes, but "the positive effects of a human moment can last long after people…have walked away,"wrote Hallowell. "People begin to think in new and creative ways; mental activity is stimulated." But, he warns: "I can tell you without a doubt that virtually everyone I see is experiencing some deficiency of human contact…People feel lonely, isolated, or confused at work." Eight years later, with our overreliance on e‐mail and technology, the situation has not improved.

Open Work Environment

• Best for teams that have a high degree of interdependence (execution) or where diversity of thinking produces the optimum result (innovation).

• Focus on creating multidimensional relationships, decreasing hierarchy, increasing access to people/information and project data immersion.

• Establishing Behavior Norms Critical for High Collaboration– Can be interrupted at any time.

– Free to join any conversation.

– Teams set majority of rules and encouraged to establish a unique personality

• Important to Compensate for Privacy Loss and Increase in Stress– Extreme casual

– Living Room Retreat & Recreational activity

– Dedicated Privacy Rooms

– Life Happens

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Coming to Your Neighborhood

• Out there in some garage is an entrepreneur who's forging a bullet with your company's name on it. You've got one option now – to shoot first.

Gary Hamel

• The French Nicks

• How many garages are working in your space now?

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?

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Dr. Rita Engler, Associate Dean and Professor Innovation and Design, Universidade do Estado de Minas Gerais, BrasilDr. Greg Sedrick, P.E. Director and Professor Graduate Engineering , Christian Brothers University

What is your definition of sustainability?

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What is the formal definition of sustainability?

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What is the formal definition of sustainability?

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How do the two differ?

What are the advantages of implementing sustainable

design?

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and

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NIMBY

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Coors Ceramics

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What are the advantages of implementing sustainable

design?

How has your organization implemented sustainability?

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How have others implemented sustainability?

recyclablerecyclableemissions

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lightinglighting

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2012 Social Innovation AwardsWINNERS LIST:• WINNER, Best Social Investment Strategy: Vestergaard Frandsen• WINNER, Best Employee Engagement Strategy: Santander Brasil• WINNER, Best Use of New Media: Stonyfield• WINNER, Best Online Report: Nestlé Waters North America• WINNER, Best Stakeholder Engagement: SAP• WINNER, Best Product Design: Be Green Packaging, LLC• WINNER, Most Strategic Use of Philanthropic Funds: Hewlett-Packard • WINNER, Best Integrated Report: SAP• WINNER, Best Sustainability Performance: Novo Nordisk• WINNER, Best Incorporation of Ethical Sourcing/Certification: H.J. Heinz

Company

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4646

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47

48

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How have others implemented sustainability?

What will you do differently in the future to implement

sustainability?

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How do you know that is the correct path?

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[email protected]

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1


Healthcare Packaging Consortium & Its Projects (2010 - 2012) Siripong Malasri1, Ray Brown2, Asit Ray3, and Larry Rutledge4

Abstract: The Healthcare Packaging Consortium was founded at Christian Brothers University (Memphis, Tennessee, USA) in 2010. Currently, there are eight companies that are members, namely Evergreen Packaging, FedEx, Medtronic, Merck, Plastic Ingenuity, Smith & Nephew, The Pallet Factory, and Wright Medical. Its mission is to advance healthcare packaging knowledge through research and education. The consortium research work is supported by the CBU ISTA’s certified package testing commercial lab. This paper gives an overview of the consortium and its R&D projects during June 2010 to May 2012, including plastic tote distribution, water absorption of wooden pallets, correlation of peel and burst testing of pouches, peel testing analysis, and performance of recycled corrugated boards/boxes.

Keywords: Healthcare packaging, plastic totes, wooden pallets, peel test, burst test, recycled corrugated boards/boxes

Introduction

Christian Brothers University (CBU), well known for its engineering programs, is located in Memphis, Tennessee, USA. Memphis has long been recognized as a major distribution center of the United State of America. FedEx’s world headquarters have attracted many companies to place their distribution centers in Memphis. Meanwhile, Memphis International Airport has helped the city redefine itself as America’s premier aerotropolis (an economic hub extending out from a large airport into a surrounding area). According to the Greater Memphis Chamber [1]:

Memphis is home to the busiest air cargo airport in North America since 1992 Memphis is on the path of Interstate 40, the 3rd busiest trucking corridor in the U.S. Memphis has five Class I railroads passing through it: BNSF, CSX, Union Pacific, Norfolk Southern, and

Canadian National The Port of Memphis is the fourth largest inland port in the U.S. 10.2% of the Memphis workforce is employed in transportation and utilities, the highest percentage among

the top 100 largest metro areas in the U.S. In addition, according to Medical Product Outsourcing [2] two companies located in Memphis are on the list of top twenty medical device companies in the world, i.e., Medtronic (ranked 4th) and Smith & Nephew (ranked 19th). The Healthcare Packaging Consortium was founded at CBU on June 1, 2010, with seven founding companies, i.e., Evergreen Packaging (www.evergreenpackaging.com), FedEx (www.fedex.com), Medtronic (www.medtronic.com), Merck (www.merck.com), Plastic Ingenuity (www.plasticingenuity.com), Smith & Nephew

1, 2, 3, 4 Healthcare Packaging Consortium, Christian Brothers University, 650 East Parkway South, Memphis, TN 38104, [email protected], [email protected], [email protected], and [email protected].

2


(www.smithnephew.com), and Wright Medical (www.wmt.com). Recently, The Pallet Factory (www.thepalletfactory.com) has joined the consortium. Each year CBU works on R&D projects recommended by the consortium member companies.

In 2009, the CBU packaging lab became a commercial lab certified by the International Safe Transit Association (www.ista.org). It is currently one of eight such certified packaging labs and the only one in an academic setting within the tri-state area of Tennessee, Arkansas, and Mississippi. These labs are:

Christian Brothers University (Memphis, Tennessee, USA) FedEx Corporation (Memphis, Tennessee, USA) Global Testing Laboratories, LLC (Knoxville, Tennessee, USA) International Paper (Memphis, Tennessee, USA) Oreck Manufacturing (Cookeville, Tennessee, USA) Packaging Corporation of America (Bentonville, Arkansas, USA) Sonoco Products Company (Nashville, Tennessee, USA) Triad Packaging (Bristol, Tennessee, USA)

Fig. 1 shows some lab equipment available at CBU packaging lab and the remaining sections of this article describe some of these R&D projects. Well-maintained pieces of equipment are needed for R&D work.

Figure 1. Lab Equipment

(a) Drop Tester, (b) Vibration Table (c) Compression Table (d) Temperature/Humidity Chamber, (e) Altitude Chamber, (f) Thermoformer

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Figure 1. Lab Equipment (continue)

(g) Sample Table, (h) Mullen Punching Strength Tester, (i) Edge Crusher, (j) Tensile Tester, and (k) 3D Printer

Distribution Tote Testing Problem Statement Healthcare products are typically shipped from manufacturers to distribution centers of retailers or large drug store chains. At this distribution phase, products are well organized and shipped in large quantities. Pre-shipment tests, such as ISTA test procedures, are well established for this distribution phase. Upon arriving at a distribution center, however, the items are removed from the original packaging and mixed with other packages for shipment to a final destination. Products of various shapes, sizes, and content are often placed randomly in partially-filled plastic totes. Damage to products often occurs during this distribution phase. There are no pre-shipment tests established, nor good practices recommended to prevent damages to the products during this phase of the distribution cycle.

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Research Findings

Two identical plastic totes with the same partially-filled contents were shipped. The contents were placed randomly in one tote but well organized in the other. Various product damages occurred in the randomly-filled tote. [3]

A bubble wrap study indicated that placing a layer of 3/16” bubble wrap sheet reduced impact acceleration by 23% while using 5/16” bubble wrap reduced by 34%. [4]

An air pillow study indicated that placing air pillows at the top of a partially-filled tote reduced the impact acceleration by 15% [4]. In addition, air pillows reduced subsequent impact accelerations [5].

Validation through drop and vibration tests showed using 5/16” bubble wrap at the bottom together with air pillows at the top of a tote was most effective [4].

Using a data logger (also known as saver or recorder) to monitor tote handling was recommended [6]. Drop heights could be estimated from impact accelerations obtained from a data logger using the equation below, given that the data logger was placed the same way it was used in this study.

y = 0.5243x – 3.4853

where y = drop height (inches) and x = saver’s impact acceleration (g).

Water Absorption of Wooden Pallets Problem Statement Wooden pallets with boxes containing healthcare products are often left outdoors for storage purposes. Even though the boxes are covered from the top to the sides, rainwater could penetrate up through the bottom of the pallet and damage the bottom layer of the boxes. Research Findings

A comprehensive study of new wooden pallets [7] indicated that water penetration could be up to about 4 inches, which could reach the top of a typical widely-used GMA (Grocery Manufacturers Association) pallet. Thus, good drainage of the pallet storage area is important to prevent water accumulation.

Water penetration is slightly higher in hardwood than in softwood pallets. The rate of water penetration was faster in hardwood than in softwood pallets. Heat treatment, which is used to eliminate pests, had little effect on water penetration in new wooden

pallets.

Correlating Peel and Burst Test Data for Unrestricted Pouches with Fin Seal Edges Problem Statement Industry standards for the testing of the integrity of the sealed edges of typical pouches fall into two major types, i.e., peel testing [8] and burst testing [9, 10]. If the two tests can be properly correlated, suppliers can use the single, faster burst testing technique to provide the peel test values directly to production and quality control personnel. Faster corrective actions would increase productivity and reduce labor and material costs.

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Research Finding

When a pouch has roughly the same width and length, the correlation of the peel force (FP) to the bursting force (PB) can be derived as [11]:

L

w

wP

FR

B

P

2

1/

where w and L are interior width and length of unpressurized pouch, respectively. Ideally, the ratio R should be 1. The model above was validated by lab data obtained from peel and burst tests.

Peel Test Analysis

Problem Statement The use of flexible sealed pouches for protective product containers has gained wide acceptance in the medical device industry, where atmospheric contamination of the product must be kept to a minimum if not eliminated entirely. Such containers typically consist of two flat impermeable or semi-permeable membranes “sandwiched” together and sealed on three sides as supplied by their manufacturer. This permits the medical device manufacturer to insert a product under appropriate sanitary conditions and then seal the remaining open side to form an air-tight protective capsule for shipment of the product. The integrity of the seal is quantified by the force necessary to peel the two membranes apart. There are three methods, i.e., unrestrained, 90o restrained, and 180o restrained, to determine this force, however most companies choose only one for testing their product. A research [12] was conducted to investigate possible differences in results from the three methods and to provide a standard for comparing results from future tests. Research Findings Industry standards for the testing of the integrity of the sealed edges of the pouch are set forth by ASTM (American Society for Testing and Material) specifically, ASTM F88/F88M-09 [16]. In all, ninety peel test runs were done on samples prepared from sterile high density poly-ethylene, provided by Smith and Nephew. The pouch samples were all cut into one inch by three and half inch strips with one inch adhesive on each strip. All of the pouches were sealed using the same adhesive and sealing processes. All tests were run at room temperature using either unrestrained, 90o restrained, or 180o restrained tail configuration at a jaw separation speed of 1 inches/min. The maximum peel force reached during each test run was recorded.

The unrestrained results had an average value of 1.86 lbf and a standard deviation of 12.6% of the average value. The 90° restrained results had an average value of 1.33 lbf and a standard deviation of 14.3% of the average value. The 180° restrained results had an average value of 3.87 lbf and a standard deviation of 4.67% of the average value.

The unrestrained results have a difference of 0.53 lbf from the 90° restrained results. However, the 180° restrained results are at least twice as large as the other results.

The 180° restrained results were the most consistent from the three tests. The 180° restrained results may be the most consistent because it had a more stable constraint applied to the sample.

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Performances of Recycled Corrugated Boards/Boxes Problem Statement The use of recycled corrugated boards and boxes has gained wide acceptance in the packaging industry where sustainability has become a priority of consumers. However, the strength of recycled corrugated boards/boxes could be reduced, especially under extreme environmental conditions. Research Findings In this research [12], edge crush tests (ECT), burst tests, and compression tests were performed on both virgin and recycled corrugated boards. All tests followed TAPPI standards [13, 14, 15]. Virgin and recycled boards/boxes, split into seven different categories according to size and material, were tested at standard conditions (73° F and 50% relative humidity) and at extreme conditions (90° F and 90% relative humidity).

Edge Crush Test: At standard conditions, both virgin and recycled cardboard matched or exceeded the determined ECT. At extreme conditions, both are reduced below the industrial listings; however, the recycled samples were reduced much more significantly. As seen in Graph 1, the percentages for recycled cardboard are consistently below 50% of the determined ECT while the virgin samples were closer to 65%.

Burst Test: At both conditions, virgin material is considerably stronger than its recycled counterpart. Due to its high rupture points, virgin cardboard showed a larger percent drop than recycled cardboard. Even with the higher percentage drop, the virgin cardboard at extreme conditions is stronger than recycled cardboard at standard conditions.

Compression Test: The virgin boxes are stronger at both conditions. Additionally, the virgin boxes show a lower percentage change for each category. This shows the humidity had more effect on the recycled boxes.

Virgin cardboard tested stronger than recycled cardboard in every test, despite identical industrial strength listings. In extreme conditions, the difference between recycled and virgin cardboard increases. If a company is striving towards sustainability, one option would be to use higher rated recycled cardboard material in place of virgin material.

Conclusions This article provides readers with an overview of the Healthcare Packaging Consortium at Christian Brothers University and some of its research projects. Current active projects include:

Seal Width Integrity (Sponsored by Merck Consumer Care) Correlation between Burst Testing & Peel Testing (Sponsored by Smith & Nephew) Performance of Different Pallet Materials and Styles Under Diverse Handling and Environmental

Conditions (Sponsored by FedEx) New projects are added annually by the companies of the consortium. These projects provide an excellent undergraduate research opportunity [17] in healthcare packaging. Additional information can be found at the consortium website at www.cbu.edu/HPC, Facebook Page at www.facebook.com/CBUHPC, or contact the first author via [email protected].

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References

1. www.memphischamber.com 2. www.phcconsulting.com/WordPress/2011/02/22/top-medical-device-companies-2011/ 3. Larry Rutledge, Siripong Malasri, and Anthony Lawrence, “Distribution Tote Testing,” Proceedings of the

2011 International Transport Packaging Forum, International Safe Transit Association, Orlando, Florida, April 18-21, 2011.

4. Siripong Malasri, Robert Moats, John Archer, Paul Shiue, Ray Brown, and Larry Rutledge, “Plastic Tote Drop Impact Study,” Journal of Packaging, Institute of Packaging Professionals, January 2012.

5. Siripong Malasri, Phyo Aung, Katy Moser, Matt Warren, Rhett Jordan, Mallory Harvey, and Alvin Siow, “Subsequent Impact Acceleration Analysis of Air Pillow Study,” Proceedings of the MAESC 2012 Conference, Memphis, TN, May 1, 2012.

6. Siripong Malasri, Alvin Siow, Katy Moser, Mallory Harvey, Phyo Aung, Matt Warren, Rhett Jordan, Evan Edwards, and Paul Shiue, “Estimating Drop Height from Saver’s Impact Acceleration,” Proceedings of the MAESC 2012 Conference, Memphis, TN, May 1, 2012.

7. Siripong Malasri, Ali Pourhashemi, Phyo Aung, Mallory Harvey, and Robert Moats, “Water Absorption of New Wooden Pallets,” Internal Report, Healthcare Packaging Consortium, Memphis, TN, June 2012.

8. ASTM Standard F88/F88M-09, Standard Test Method for Seal Strength of Flexible Barrier Materials, 2009.

9. ASTM Standard F2054-07, Standard Test Method for Burst Testing of Flexible Package Seals using Internal Air Pressurization within Restraining Plates, 2007.

10. ASTM Standard F1140-07, Standard Test Methods for Internal Pressurization Failure Resistance of Unrestrained Packages, 2007.

11. Ray Brown, Asit Ray, and Samuel Tsai, “Correlating Peel and Burst Test Data for Unrestricted Pouches with Fin Seal Edges,” Proceedings of the MAESC 2012 Conference, Memphis, TN, May 1, 2012.

12. Kalli Powers, Matthew Warren, and Ray Brown, “Packaging Analysis,” Proceedings of the MAESC 2012 Conference, Memphis, TN, May 1, 2012.

13. TAPPI T839 om-08, Edgewise Compressive Strength of Corrugated Fiberboard using the Clamp Method, 2008.

14. TAPPI T807 om-11, Bursting Strength of Linerboard, 2011. 15. TAPPI T804 om-06, Compression Test of Fiberboard Shipping Containers, 2006. 16. ASTM Standard F88/F88M-09, Standard Test Method For Seal Strength Of Flexible Barrier Materials 17. Siripong Malasri, "Undergraduate Research in Healthcare Packaging," Proceedings of the ASEE Mid-

Atlantic Conference, American Society for Engineering Education, Philadelphia, Pennsylvania, October 29, 2011.

Authors:

Siripong Malasri – Dr. Malasri is Professor of Civil Engineering at CBU, where he also serves as Packaging Department Chair and Healthcare Packaging Consortium Coordinator. He obtained his Ph.D. from Texas A&M University and is a registered professional engineer in Tennessee. Dr. Malasri was instrumental to the establishment of the packaging engineering program at CBU during his term as engineering dean from 1999-2005. His background includes construction management, structural engineering, solid mechanics, materials testing, artificial intelligence, optimization, and packaging. He is a member of IoPP, TAPPI, and NSPE. Ray Brown – Dr. Brown is Professor Emeritus of Mechanical Engineering at Christian Brothers University. He earned his Ph.D. from the University of Notre Dame. He has also served as mechanical engineering department chair and engineering dean at CBU. His interests include mechanical and thermal systems. He is a member of ASME. Asit Ray – Dr. Ray is Professor of Chemical Engineering at CBU. He earned his Ph.D. from Lehigh University. He spent seven years in the polymer industry and is actively engaged in laboratory research in polymeric and biomaterials. He teaches various packaging classes at CBU, including principles of packaging, distribution and medical device packaging, and sustainability. He is a member of IoPP and AIChE. Larry Rutledge – Mr. Rutledge is retired from FedEx where he managed FedEx Packaging Design and Development department for over 18 years. Larry earned his B.S. in Engineering Technology from Memphis State University and M.S. in Technical Education from University of Memphis. Larry has a diverse background in mechanical systems design, facility planning, industrial engineering, project management, package testing and design and logistics solutions. Larry is past Chairman of the IoPP Transport Packaging Committee, Board of Directors for ISTA, and Board of Director for Michigan State University Consortium on Distribution Packaging. Larry is continuing his Packaging Career as a consultant. He also serves as Manager with CBU's ISTA Certified Lab.

______________________________________________________________________________________________________

_______________________________________________________________________________________________________

Siripong Malasri, Ph.D., P.E., CPLP Technologist

Editor-in-Chief, International Journal of Advanced Packaging Technology

Healthcare Packaging Consortium, Christian Brothers University, 650 East Parkway South,

Memphis, TN 38104, USA. Phone 1-901-321-3419; Fax 1-901-321-3402; Email [email protected]

Date: October 28, 2013

Dear Readers: The original paper entitled “Effect of High Temperature on Compressive Strength and Impact Acceleration of New Softwood Pallets” by Malasri, Pourhashemi, Brown, Harvey, Godwin, Aung, Larney, and Moats has been replaced by a more comprehensive article entitled “Effect of Temperature on Static and Impact Properties of New Softwood Pallets” in the International Journal of Advanced Packaging Technology, Vol. 1, No. 1, 2013, at:

http://technical.cloud-journals.com/index.php/IJAPT/issue/view/9

Sincerely,

Siripong Malasri Editor-in-Chief, International Journal of Advanced Packaging Technology Director, Healthcare Packaging Consortium

http://technical.cloud-journals.com/index.php/IJAPT/issue/view/9

11/17/2012

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2012 HPC Fall Meeting, Christian Brothers University

3:00– 4:30 p.m., November 15, 2012

Note. The manuscript of this presentation will be published in International Journal of Applied Science and Technology, Vol. 2, No. 8, December 15, 2012.


11/17/2012

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y = 0.0239x for x <= 83 min (R² = 0.9937)

y = 0.3742ln(x) + 0.3679 for x > 83 min (R² = 0.9703)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

0 250 500 750 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250

Water Pen

etration Height (in.)

Time (mins)

SW N 11

0.0

0.5

1.0

1.5

2.0

2.5

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3.5

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Water Pen

etration H

eight (in)

Time (mins)

New Softwood Pallets

SW N 11

SW N 12

SW N 13

SW N 21

SW N 22

SW N 23

SW N 31

SW N 32

SW N 33

AVG

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y = ‐7E‐06x2 + 0.028x for x <= 45 mins (R² = 0.9977)y = 0.43ln(x) ‐ 0.1776 for x > 45 mins (R² = 0.9839)

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

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etration H

eight (in)

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New Softwood Pallets

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etration H

eight (in)

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Effect of Heat Treatment

SW N

SW N HT

HW N

HW N HT

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0.0

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0 200 400 600 800 1000 1200 1400 1600

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etration H

eight (in)

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Comparison of New and Used Softwood Pallet SpecimensSWN = New Softwood, SWU = Used Softwood

SWN

SWU

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