Product Design
25% of ChE’s 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
• Let’s look at some examples.
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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
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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 Sol’n
Heat Patch/Hand Warmer
• 4Fe(s) +3 O2Fe2O3
+ 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
Solid
Cl
Meta-stable
Solid-Liquid
Line
eq
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
• Let’s look at some examples.
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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
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Toothpaste
Shampoo
Deodorant
Mouthwash
Dish soap
Active Ingredients
– Sodium
monofluorophosphate
0.76%
• Inactive Ingredients
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Glycerin
Sorbitol
Hydrated silica
Propylene glycol
Sodium bicarbonate
Aluminum oxide
Water
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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
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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
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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
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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
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Water
Cyclomethicone
SD alcohol40
Tripropylene glycol
Dimethicon
Propylene Glycol
Phenyl trimethicone
PEG/PPG-18/18
Dimethicone
Fragrance
Shampoo
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Ingredients
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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
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Ingredients
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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
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Water
Sodium Laureth sulfate
Cocamidoproply betaine
Cvocamide DEA
Coco-Glucoside
Perfume
Phenoxyethanol laureth-2
Benzyl Alcohol
Sodium Benzoate
Propylene glycol
Citric Acid
Polyquarternium-10
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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
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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
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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 • 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
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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
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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)
– Kd=Co/Cw
– δ=(μe Vhand Whand/(2 Papp))1/2
– Easy to apply
Fick’s 1st Law
Distribution Coeff
Reynolds’ Equation
Lubrication theory
– Friction Coefficient = (μe Vhand /(2 Papp Whand))1/2
– Figure of Merit = High Flux, low friction
2 DC o Papp
(D/  )(C o / K d )
FM 

1/2
(  e Vhand /(2 Papp Whand ))
K d  e Vhand
FM Values
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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
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Flavor controlled by
– Ingredients
• Partial Pressure of Flavinoids to
Nose
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Creaminess
– Controlled by
• processing conditions
• Ingredients
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Smoothness
– Controlled by
– Processing condition
• Ice Crystals less than 100 microns
– Ingredients
• Fat, air bubbles
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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
– 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
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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
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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
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• 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.
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• Extinguishing Media: Does not burn or support combustion. Use
water, CO2 or dry chemicals.
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• 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.
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• Fire and Explosion Hazards: None
Section IV. Reactivity Data
• Stability:
Stable
• Conditions to Avoid: Dilution of product into streams or other
bodies of water.
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• Incompatibility:
Solution is mildly corrosive to steel. Store
solution in plastic or rubber or 304, 347 or 316 stainless steel.
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• Hazardous Decomposition Products: None at normal conditions.
If dried crystals are heated above 400C toxic fumes of copper
oxide and sulfur may evolve.
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• 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.
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• Skin:
Non-toxic. Avoid contact with skin. Non-irritant
(rabbit)
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• Eyes:
Causes moderate, but temporary eye irritation.
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• Inhalation: Inhalation of mist may cause irritation to the upper
respiration tract.
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• 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.
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• Skin:
Wash thoroughly with soap and water. Remove and
wash contaminated clothing before reuse.
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• Eyes:
Immediately flush eyes with plenty of water for 15
minutes. Hold eyelids apart during irrigation. Call physician.
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• Inhalation:
Remove person to fresh air and call a
physician.
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• Carcinogenicity:
None
Section VII. Handling Precautions
• Personal Protective Equipment:
Chemical Safety Goggles
Rubber gloves and rubber apron may be worn.
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• 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.
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• 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
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Aquatic Toxicity:
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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.
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• 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
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• HMIS Codes:
• Health: 2 Fire: 0 Reactivity: 0 Protection: B
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• 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