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Innovative Packaging for Pest Control Product

  • Prime : 35 000€
  • Deadline : 31/08/2018

Description

What is The Problem?

Some bait boxes are subject to porosity, water loss, fragility, stress cracking

The seeker wants to (in this order):

  • Stop all potentiality of porosity of the plastic material in order to avoid effects such as water loss (leading to “swelling of the polystyrene box “, “the boxes become sticky”)
  • Eliminate all risks of chemical interaction between the plastic and the formulation

While keeping the same functional principle and design of current bait boxes


What is The Context 

  • Production process

  • Container
    • Molded, to include opening device
      • Junctions, where the wall thickness is ~ 200 µm – to produce a locally restricted breakable part
  • Filling – plastic material will come into contact with product that contains:
    • Water
    • Mild acids (such as citric acid, pH 5.5)
    • Proteins
    • Polar solvents (such as polyols)
    • Mono-, Di- and Triglycerides (such as plant oils) partly unsaturated
    • Carbohydrates
    • Sugars
    • Preservatives
    • Flavor components
  • Lid sealing
    • Ultra-sonic welding

 


What are The Desirable Characteristics? 

Financial:

  • Box < 14 cents/box (after filling & sealing)
  • No increase above 10%
  • Suppliers in western Europe

Technical:

plastic material must

  • During the production process
    • Be useable for injection molding process
    • Be useable for ultrasonic welding (eventually heat sealing)
    • Must maintain the same functionality of the bait box (breakable tabs: a thin wall thickness, e.g. 200µm, to produce a locally restricted breakable part), insuring a long and full stability of the formulation
      • Security “No cut when box opened”
      • Same ease of use (end-user opening experience) “easy opening”
  • At room temperature within 3 years and in contact with the biocide formulation
    • Be water vapor proof (negligible loss of moisture during 3 years)
      • No gel leakage
      • Water evaporation
    • No change in elasticity (become brittle)
      • A material resistant over time to the chemical formulation of the pest control product. The duration taken into consideration for the resistance of the box to the chemical formulation would be typically 3 years

Design options

  • The design of the box might slightly change, to suit the needs explained above.
    • A two-layer design would be acceptable for instance
    • Additional coating could be also considered to fill the porosity of the box
  • No or limited production process change
    • No/Limited box design change
    • No/limited sealing process change
    • No mold change (preferred – not a blocking point)

Environmental:

  • It would be a plus (“nice to have”) after the other criteria
    • Bioplastic – or any material which is biodegradable
  • Keeping the same (even improving) the same environmental parameters than
    today
    • No toxic element

 


Selection Criteria

Different solutions are possible. Find below their order of preferences

  • No box design change
    • Other plastics
      • Multi-layer
    • Lid/cap changes (welded)
    • Limited change in production process
      • Opening device change
      • Not impact on the safety utilization
  • Box design change
    • Mix plastic film + box
    • Metal is not excluded (but cost impact is key)
      • This could impact the process

Performance

  • Water permeability
    • Goals: less than 10% (after 3 years, weight loss)
  • Resistance to solvents
    • Contact plastic – solvents
      • Interaction tests (visual stress cracking + sealing tests)

 


Existing Solutions That Won’t Be Considered for This Challenge

Solutions already considered and not validated include:

  • Thermo – molded

  • Materials to be excluded:
    • Glass

 


Proposed Format for The Writing of The Solution

The solver should write a solution following the Frame described below:

  • Choice of solution
    • No box design change
      • Other plastics
      • Multi-layer
      • Lid/cap changes (welded)
      • Limited change in production process
      • Opening device change
    • Box design change
      • Mix plastic film + box
      • Metal is not excluded (but cost impact is key)
      • This could impact the process
  • Performance
    • Level of porosity reduction obtained (water permeability)
      • Goals: less than 10% (after 3 years, weight loss)
    • Level of chemical interaction reduction attained (resistance to solvents)
      • Contact plastic – solvents
        • Interaction tests (visual stress cracking + sealing tests)
  • Business/Market potential (big picture/estimated)
    • Costs
  • Detailed explanation of the solution
    • Free format

 


Rewards

  Design changes
&
limited changes
on production
process
Design
changes
&
NO changes
on production
process
NO Design
changes
&
NO changes on
production
process

Water permeability 

<10% after 3 years

AND
Resistance of plastic
(no stress cracking, no
leakage)

Theorica solution3 000€8 000€12 000€
If Proven
solution
(3 years)
9 000€18000€ 35 000€

 

The maximum reward would be 35 000€

  • For selected theoretical solutions, the payment will be upfront
  • For proven solutions, the payment will be as follows:
    • 50% of reward after accelerated test (12 weeks at 35°C) success
    • 50% at the end of the first 12 months of test at ambient room temperature storage

Contact the Challenge Manager if you have any question:

emilia@hypios-experts.me

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