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MBE 6051 Sustainable Green Manufacturing

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志远 刘

on 15 April 2014

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Transcript of MBE 6051 Sustainable Green Manufacturing

Manufacturing and remanufacture
MBE 6051 Sustainable Green Manufacturing
1. Introduction
Cotton buds  consist of a small wad of cotton wrapped around one or both ends of a short rod, usually made of either wood, rolled paper, or plastic.

3.Problems Identification
Life cycle analysis
1. Introduction
2. Background
3. Problem Identification
4. Design Objective
5. Possible solutions for the problem
6. Life-Cycle Analysis (LCA)
7. Manufacturing and Recycle
8. Conclusion

Green Cotton Bud
ZHANG XU 53305859
WEI LIYA 53308272
LIU ZHIYUAN 53517113
CHEN SIYA 53372245

They are commonly used in a variety of applications including first aid, cosmetics application, cleaning, and arts and crafts.
Because of the widely applications, the cotton buds consumption is tremendous.
There are many kinds of Cotton buds.
Different standard, size, quality.
Most of cotton buds' stick are made by wood or plastic
Most of cotton buds are double - headed.

Currently use a cotton bud, the use of bamboo or wooden sign as a cotton bud, cotton wrapped around one end components. 
Because cotton is
disposable products
, cotton bud will cause extensive use of bamboo or woods, that’s
waste of non-renewable resources
In Hong Kong 2012, cotton wood/buds recorded a growth of 2% with HK$77 million value sales. Even use wood and bamboo as the basic materials of swab, these substantial waste of resources is not conducive to
eco-friendly construction

Waste of non-renewable resources-wood stick
First Focus: Parts, Materials
Second Focus: Manufacturing and remanufacture
waste of non-renewable/non-recycle materials
toxic glue do harm to the environment
packaging use non-environmental friendly material
Manufacturing process consumes too much energy
Materials recycle and remanufacture
toxic glue do harm to the environment
packaging use non-environmental friendly material
First Focus: Parts, Materials
waste of non-recycle material --cotton
Second Focus: Manufacturing and remanufacture
Manufacturing process consumes too much energy
Materials recycle and remanufacture
Cradle to Cradle Concept in Product Life-Cycle
Problem Identified by

Non-reusable and non-recyclable materials
Non-recycled materials
Non-renewable materials
energy consumption
recycle of materials
(Al, paper)
Alternative design
Design a green cotton swab
reduce material used
make sure it's sanitation and convenient to use
use recycle materials
using green energy to manufacturing

The cotton tip consists of three water-prove cotton layers, wrapping one by one.
● this new design save considerable consumption of cotton swabs
● in terms of cost on manufacturing, this design would certainly reduce the costs of the but part material
● using the non-toxic plant gum as the adhesive

New design of cotton tip and adhesive
Shorter paper bud
● using paper to make the bud part costs much less woods, which is more environment friendly than direct use of wooden bud
● besides changing the material, reducing the length of the bud somewhat costs less wood

Disruptive design of bud fixing unit Illustration

● this unit is made up of aluminum, which could be easily recycled
● providing the needed length for usability

Goal and scope definition

Goal: to compare the new design of cotton bud with the present one
System boundaries: manufacturing phase, packaging phase, and the use and disposal phase of the product life cycle

System functions and functional units
System: reduction of wood, cotton and plastic usage
Function: reduce the use of wood and plastic
Function unit: 10T of wood, 1T of cotton, 1kg plastic

Life cycle inventory
About 94% of cotton bud’s weight is from wood. So, with calculation, there was about 47 million tons woods cost because of cotton buds production in 2010.

We used both the new paper which is made of straw and waste paper to make stick, this measure can not only save the woods which are used to make cotton buds, but also can improve the negative impact caused by burning straw in mainland.
The cotton tip consists of three water-prove cotton layers, so the consumption of cotton is 1/3 of primary product.

We will use paper as package, so the plastic usage will be eliminated.
Consumption of cotton bud in China
Unit:10 thousand tons
● nontoxic to human body
● affordable price to household use
● proper length to serve usability
● relative policies and standards

Using paper package other than plastic one
● using paper package would make package recycling much easier
● paper package costs less

cotton as non-recycle material, we can only use it for one time.
sometimes we only use one side of the cotton bud, and then throw it away, it's waste of material
Specification of the machine
Input: 380V,12KW/machine
Size: 10.0*1.0 *1.4M
Output: 1000-1200 stick/min
Too much energy consumes during manufacturing process.
In current market, there are 3 basic package methods: single use paper bag; single use plastic bag and paper box. Those paper and plastic are not bio-degradable and also causes environmental issues during packaging process.

The glue used during manufacturing is toxic,
which will do harm to the environment and user.
The materials the cotton buds used
can not be recycle
toxic glue use
Manufacturing process
Paper recycle
raw materials
used in the production of cotton buds are cotton, sticks
Injection moding made the cotton buds' container
material: plastic
The sticks come out from the stick chute through the un-loader wheel. From the un-loader wheel the sticks move through the conveyor chain passing through the paste receptacle.
Drying and sterilization of the cotton buds are achieved at the heater, where the cotton buds are conveyed through the heater chains.
After drying, the cotton buds are either directly transported to the Auto Packaging Machine or manual packing.
Finished products are stored in the Warehouse after passing through Quality Assurance Section.
Aluminum recycling process
Meeting record:
Feb 20th 21:30:After-class studying about Cradle to Cradle concept and clarified responsibilities also assigned tasks of each group member.
Feb 27th 21:30: Mainly discussed design prototypes we had and presented views and opinions.
Mar 2nd 15:00: Submission of each aspect and designed PPT.
Mar 5th 15:00: Final discussion about mid-presentation and did the rehearsal for presentation.

Q & A
Little things can make the earth a better place.
Product on market: 8cm-10cm(2 ends)
Our design: 2.5cm(1 end)
save 3cm-5cm/2 ends
Life cycle inventory
Full transcript