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1、Innovative Temperature-ControlledPackaging&Design TechnologiesKevin ODonnellTechnical DirectorTegrant Corp.,ThermoSafe BrandsCold Chain Smart Solutions,Barcelona Spain20 January 2011,2,Outline,2,My BackgroundProduct DevelopmentsSystems and Software DevelopmentsData Logging DevelopmentsPassive System
2、 ImprovementsConclusions,3,My Background,3,30 Years of packaging experiencePrinciple Packaging Engineer,Abbott Laboratories(Retired 2005)26 Years of cold chain experienceChair-IATA Time&Temperature Task ForceMember-USP Expert Committee on Packaging,Storage&Distribution(2010-2015 Cycle)Temporary Advi
3、sor-World Health Organization,4,Product Developments,4,InsulationRefrigerants,5,Product Developments-Insulation,5,EPSAdditives to enhance R-value NeoporeDesigns to enhance natural convectionRecycled contentPURDesigns to enhance natural convectionVIPNew suppliers offering higher R-valueImproved desig
4、ns offering fewer edge leaks and tougher materialsOtherHybrid designs with built in heating and cooling(i.e.Rapid evaporation technology,zeocool)Completely sustainable materials,6,Product Developments-Refrigeration,6,Expansion of Phase Change MaterialsPCMs from-40C to+40CReplacements for dry iceCRT
5、materials2-8 materialsMacro and micro encapsulationNew formatsPCM suspended in bricksEvaporative coolingBottlesCombined insulation and PCMSustainabilityMore and more materials are completely sustainableFormats that can be returned and reused,EPS vs PUR vs VIP,Correlation between size and R-valueR-va
6、lue goes up package size goes downR-value goes up weight goes downR-value goes up container cost goes up,EPS PACKAGING Size,PUR PACKAGING Size,VIP PACKAGING Size,70lbs,40lbs,20lbs,PAYLOAD 1L,PAYLOAD 1L,PAYLOAD 1L,Enhanced Phase Change Materials(PCM),Salt HydratesParaffinsEutectic SaltsInorganicOrgan
7、icHeavy WaterNon-Paraffin OrganicsFatty AcidsAlcoholsPolymersTypical Latent Heat=100-250 KJ/KgTypical Melting Temp=-70C to 100C,PCM Comparisons,Phase Time=Density x Volume x Latent Heat,Refrigerant Comparison,Cost Comparison,w/water-based gel,w/PCM,Weight&Size Comparison,w/water-based gel,w/PCM,Cost
8、 Vs Control New Materials,14,Systems&Software Developments,14,CAE(Computer Aided Engineering)Chamber AccuracyQbD(Quality by Design)Enhanced Protocols,QbD,15,Systems&Software Developments-CAE,15,CAD 3D modelingSimulation FEA/CFDPayload optimization softwareVirtual prototyping,16,Systems&Software Deve
9、lopments-Testing,16,Chamber AccuracyImproved data loggingFront end software helps tying data togetherRemote access labsQbD(Quality by Design)Adoptions of these principles more prevalentImproved materials characterization,Concept,Design,Custom Prototype,Testing,Analysis,Passing?,YES,NO,Qualification,
10、Production,New Prototype Needed?,YES,NO,START,FINISH,RE-DESIGN,Concept,Prototype,Testing,Analysis,START,FINISH,Qualification,1 Week,1 Weeks,2 Weeks,3 Weeks,1 Week,8 Weeks,3 Weeks,=12 Total Weeks,=7 Total Weeks,Production,Simulation-DrivenProduct Development,19,Data Logging Developments,SmallerReal t
11、ime data collectionTracking and problem solving in-lineWireless GPSMkT,temp,humidity all in one logger,19,20,Passive System Improvements,20,Total Cost of AcquisitionOptimized DesignsImproved Temperature ControlSpeed to MarketLast MileSustainability,21,Passive System Improvements,21,Total Cost of Acq
12、uisitionReduced weight Lower freight costsLarger payloadsReduced or eliminated bench timeReduced conditioning requirementsSimpler designs Optimized DesignsQbD methodsAbility to test more variablesOptimize use of refrigeration and insulation quantity and placementSensitivity analysisAnalyze against m
13、ultiple profiles,22,Passive System Improvements,22,Improved Temperature ControlImproved R-valuePCM phase within payload rangeFewer excursionsImproved material characterization Speed to MarketVirtual prototypingModeling versus chamber testing,23,Passive System Improvements,23,Last MileLonger duration
14、Better understanding of shipping lanesTrack and traceRecharging in cold storage SustainabilityReduced weightReusable materialsImproved recycling,24,Conclusions,Dramatic Changes But Still Not ThereChallenges:Not there with last mileInsulation,refrigeration,systems,and data logging will continueChanges need to be vailidatedImproved sustainabiltiyIndustry consences on standardsControl of ambients and lane temperatures,25,Thank You!Kevin ODonnellThermoSC847-632-9649,
