Sustainable TOP CAP packaging for glass containersBlind

in 3D Modeling Design held by CARTONPLAST
Contest Ended, Winner(s) have been selected.
Description:
Packing glass-containers for transportation is usually done palletized by using plastic layer pads in-between the glass containers and on top by using a cover with is called TOP CAP.
Until now the TOP CAP which is used almost only is made from cardboard.
As the actual cardboard-TOP-CAP is a one-time-use packing, we are looking for an alternative design to replace this cardboard TOP CAP by a
• Reusable
• Hygienic Cleanable by an industrial process
• Recyclable
• Robust and sustainable
alternative.
Wants:
We need 3D-Designs to understand the way the idea works.
Don't Wants:
Just a copy of the existing solution in other materials
Ideas which are already in the market
Ideas which are already protected by patents
Ask for Sample:
Samples not needed for now.
Software:
  1. SolidWorks
  2. Autodesk Inventor
  3. CATIA V5
  4. STEP/STP 3D Modeling
  5. Parasolid Modeling

Entries

1st Winner
#76 top_cap_06b by DaBu
Minor changes to the previous model.
more
Nov 22, 2021 16:31
2nd Winner
#100 Sustainable TOP CAP packaging for glass containers by CDdesignSTUDIO
With stopper
regards
Armin
more
Nov 24, 2021 12:40
#10 TOP CAP V1 by designitzsolt
Hi,
Please check my presentation , I wil send the 3D model too . If you like this idea please let's talk about this project, I'm sure we can develop a great solution for you . I want to send my first version , please check it. Thank you in advance
Best regards, Zsolt
more
Nov 6, 2021 12:11
#72 Top cap Model 5 by Hamed1
Improved concept
Regards.
more
Nov 21, 2021 18:23
#86 Sustainable TOP CAP packaging for glass containers by CDdesignSTUDIO
Simplified concept
regards
Armin
more
Nov 23, 2021 18:19
#103 HDPE_TOPCAP by Otto Katz
Hello, Cartonplast!
The material for my TopCap is recycled HDPE or PE wich is used, for example, in the manufacture of containers for auto oils, etc. In this way TopCap fulfills a regenerative ecological function. My design is as simple as possible and devoid of any intricated mechanisms and doesnt have metal parts, while fully meeting the requirements. For folding, my TopCap has several bend zones, the material in this area is thinner than the main one and this allows it to bend easily.
I conducted an experiment - a 1mm thick HDPE plate easily folds over 200 times while maintaining its shape and strength. The folding principle can be seen in the attached file.
Now the thickness of all elements is 3 mm and the weight is 5.8 kg. I believe that it's necessary to reduce the thickness of side parts, this will help to fix bottles more tightly during packaging and also reduce weight. My TopCap doesn't require expensive press moulds to make, it can be easily made from sheet material.
I'm ready to answer any questions. looking forward to your reply.I conducted an experiment - a 1mm thick HDPE plate easily folds over 200 times while maintaining its shape and strength. The folding principle can be seen in the attached file.
Now the thickness of all elements is 3 mm and the weight is 5.8 kg. I believe that it's necessary to reduce the thickness of side parts, this will help to fix bottles more tightly during packaging and also reduce weight. My TopCap doesn't require expensive press moulds to make, it can be easily made from sheet material.
I'm ready to answer any questions.
Looking forward to your reply.
more
Nov 24, 2021 15:14
#1 HXT Top Cap by Bhavik Mistry
I have developed Hinge type design for top cap which is very easy to manufactured, assembled, operate , Transport and use for any type of bottle stacks. As you requested to make design robust(~10 years life span) i have considered HDPE material for the main Cover and side flaps. I have also used 3" Nylon straps which connects at the ends of each side flaps, it will control the side flap movement(Maximum 90 degree).
Thanks!
more
Oct 26, 2021 18:07
#45 Sustainable TOP CAP packaging for glass containers. by Nikhil Rajwade
Nov 18, 2021 8:53
#82 Sustainable TOP CAP packaging for glass containers by diogosantos
Hi, please check the presentation file.
Regards.
more
Nov 23, 2021 14:34
#6 1st Design Model Top Cap by Chaniago
Dear, CartonPlast Team
Here is my first design proposal for the project "Sustainable Top Cap Packaging For Glass Containers". With a brief description as follows:
*Dimension : 1200x1000x60mm [ LxWxH ]
*Material : Polypropylene [Pp]
*Weight : 6.2 Kg
For more details and 3D model, please see the attachment.
I will be waiting for your suggestions and feedback regarding the design.
Hopefully this design can be useful and in accordance with your expectations
Thank you
Healthy Greetings
Chaniago
more
Nov 4, 2021 8:06
#19 Simple Top Cap and Pad. by Harry S.
Please check the description in my designer entries page.
more
Nov 10, 2021 7:38
#54 Sustainable TOP CAP packaging for glass containers by ZOUHAIR
...
more
Nov 19, 2021 17:49
#73 4th Concept Design Top Cap Packaging For Glass Containers by Chaniago
Dear, CartonPlast Team
This is the fourth design concept in the "Sustainable TOP CAP Packaging For Glass Containers" project and it may be my last concept in this contest. In this design.
I tried to use the adjuster crossing lips bar method which can adjust the shape of the bottle lips with a spring mechanism.
The crossing bar is of course coated with silicone rubber so it is safe when in contact with the lip of the bottle.
So it can accommodate all types of bottle shapes. And here's a short description:
=> Dimensions: 1200x1000x55mm [ LxWxH ]
=> Thickness : 5mm
=> Weight: 8 Kg [ slightly heavier than the previous design ]
=> Material: Polypropylene + Silicone Rubber
=> Bottle Lips Diameter Range: 26mm [ Min ] - 38mm [ Max ]
For more details, please see the attachment.
I will look forward to suggestions and feedback regarding this design,
and I am very happy to be able to work with your team now, tomorrow, or in the future.
Finally, I hope this design can be useful and can help you and your team
Thank you
Healthy Greetings,
Chaniago
more
Nov 22, 2021 4:27
#83 Sustainable TOP CAP packaging for glass containers by CDdesignSTUDIO
New concept
regards
Armin
more
Nov 23, 2021 14:52
#2 Packaging Tp by Steersman
Hi. My solution is a solid unit with no hinges, made from plastic foam.
In the design, the side walls are tapered outwards so they can be stacked. And they have some additional spacing pieces top and bottom to stop them squashing into each other when they are stacked.
I have put in four spacing pieces, two on the top, and two underneath, but this number can be increased on the underside so that the tops of each bottle can it into its own cavity.
Because use IronCAD, which is not on your list, I have submitted and IGES file, which can be imported in to any 3D CAD systems you use.
I hope you like it.
Rob
more
Oct 27, 2021 11:36
#3 Top Cap by bobt
Having seen many pallets of bottles, and other products, being shipped the wasted plastic film is revolting IMO.
In most cases the 'disposable' plastic film is used as a restraining strap to keep the bottles from shifting during transport. It serves no other useful purpose.
This top cap design has two parts. Both are simple solids suitable for injection molding with whatever material you choose. The two parts, combined with fabric restraining straps, form a complete restraining system. In addition the top cap is designed to be a container for the side bars for return shipping.
The straps are cinched tight using a standard friction buckle, like a belt or backpack. The cinching is handled by slots in the two parts.
The design is publicly available at
https://cad.onshape.com/documents/0833938a1947895653bf670c/w/ec47685166cd883fc3bd1b28/e/3efa861f24fcef91b6dcd3e4
I regard this work as a public service. I will also be quite happy to accept any prize money if the design wins to support our ongoing sustainable design work.
more
Oct 28, 2021 1:59
#4 top cap by emin
That s it
more
Oct 31, 2021 16:12
#8 ARRAY V1 Top Cap by ARRAY
This top cap features an autolocking system to transform a 2d Polypropylene dieline into a functional 3D top cap. This keeps the cost low and maximizes its usees. It also allows the top caps to be flat-packed for storage and shipping.
The material I designed for is a 5mm white PP corrugate.
Thanks
more
Nov 5, 2021 21:34
#9 SUSTAINABLE TOP CAP FOR GLASS CONTAINERS (1200*1000*60 mm) by PARVINDER SINGH
Hello CARTONPLAST Team.
This is the submission of my first proposal design of Top cap.
Material: Polypropylene
Description: The concept used for your proposal is generally a hinge type. Hinges are connected with the upper side of the top cap and outer sides of the side hanging walls as shown in the picture. When you start pulling the top cap from the upper side with the help of a vacuum cup, then the sidewalls will automatically go straight with the help of gravitational rotation on hinges. The sheet packaging remains the same as cardboard packaging on a pallet. But your folding & gluing process will be removed permanently. So please check my concept and give me feedback about the required changes in my design. Hope you'll like it.
Thanks
Parvinder Singh
more
Nov 6, 2021 10:36
#11 Sustainable TOP CAP packaging for glass containers by CDdesignSTUDIO
Rubberized top cover
In 2D you have technical details.
regards
Armin
more
Nov 6, 2021 19:59
#13 Packaging Top by Steersman
Hi

Thank you for the comments, and from these, I have re-designed the Packaging Top. Please see attached. And here are my answers to your questions:

1. The principal of the concept is that the packaging top can be used by a variety of bottles.
2. The top is flat and can withstand the load of a pallet on top of it.
3. I have also included a number of air-routes on the underside. This is to minimize 'stiction' when the lids are stored in a pile, which can often happen to plastic materials, particularly if they are squashed down for any reason.
4. In terms of ‘pick and place’, there is a degree of flexibility in positioning the packaging top because the walls taper outwards towards the bottom edge, giving a 2cm gap all round when lowering one lid on top of another.
5. Material - For long lasting use, I suggest it should be cast using polypropylene. This material has moderate elasticity, and is very resilient.

Please see the attached three pictures, and an ‘IGES’ file of the design which can be imported into your 3D CAD system.

I hope this all helps, and please feel free to contact me again if you need any further help.

Best regards

Rob
more
Nov 7, 2021 12:15
#15 Sustainable TOP CAP packaging for glass containers by CDdesignSTUDIO
New concept
regards
Armin
more
Nov 7, 2021 23:54
#16 2nd Design Top Cap With Lips Locked by Chaniago
Dear, CartonPlast Team
This is my 2nd design model for your project "Sustainable TOP CAP packaging for glass containers". And in this second design I use the "lips locked" method which works to cover all dimensions of the bottle you produce so that this top cap can be used on all types of bottles. And here's a short description:
*Main material : Polypropylene with deep blue sky color
* Dimensions of the outer top cap : 1200x1000x80mm [ LxWxH ]
*Dimension inside lips locked : 1106x907mm
*Lips range adjustable : 0 - 14mm
*Wight : 4.8 Kg
For details, please see the attachment.
And of course this design still requires suggestions and feedback from you as a product user.
Working with you will certainly be very pleasant, so I am waiting for suggestions and feedback from this regarding my second design.
Finally, hopefully it can be useful and can provide a solution for you
Thankyou
Healthy Greetings,
Chaniago
more
Nov 8, 2021 19:31
#18 3rd Design Model Top Cap With Bent And Folding by Chaniago
Dear, CartonPlast Team
Morning spirit...
Here is my third design for your project "Sustainable TOP CAP Packaging For Glass Containers". In this third design I tried to make a top cap design with the bent and folding method, the same as your packing method using cardboard, only the materials and construction are different. This top cap can also be washed and reused.
Here's a brief description:
=> Dimensions: 1200x1000x80mm [ LxWxH ]
=> Thickness : 2mm
=> Weight: 3 Kg
=> Material: Polypropylene
For more details, please see the attachment
Of course, the design still requires suggestions and feedback from you as a user in the production process.
Hopefully this design can be helpful and useful for you and in accordance with what you expect
Thank you
Healthy Greetings
Chaniago
more
Nov 9, 2021 21:52
#22 top_cap_#1 by DaBu
This design tries to meet all your requirements, especially those related to ease of manufacture and durability. Check the attached document form more information.
more
Nov 11, 2021 13:36
#23 Top cap model1 by Hamed1
Hi, here is my concept.... Please send feedback if you like it.
Regards.
more
Nov 11, 2021 14:51
#24 TopCap Version 1 by coldmonk
Let me know about your likes and dislikes of this design. Will fit the 1200x1000 pallet and I've added features to enhance utility. I'll gladly accommodate any new changes you suggest. Thanks.
more
Nov 12, 2021 16:57
#27 PATELLA Sustainable TOP CAP packaging for glass containers by ZOUHAIR
...
more
Nov 15, 2021 0:20
#28 Sustainable TOP CAP packaging for glass containers by sherifelsheikh
V6.1
more
Nov 15, 2021 13:39
#29 Top cap packaging for glass containers by Kzswara
This degine is best looking and reusable and easily clean. And this pallatized adventageas is no plastic rap to use it because side safety. not glass containers breakdown in side because side safety. And is cost is not high because it is not very complicated degine.and is fit easily.
more
Nov 15, 2021 15:14
#30 FlexV3 by Bhavik Mistry
New Concept_Single Part _Flexible design
I have also attached preliminary FEA analysis to support the design.
more
Nov 15, 2021 18:27
#32 Sustainable TOP CAP packaging for glass containers by HBC DESIGN
Hi Sir,
My Concepts
thanks
Harry
more
Nov 16, 2021 10:40
#34 Sustainable TOP CAP packaging for glass containers by CDdesignSTUDIO
New concept
more
Nov 17, 2021 2:11

Discussion

Showing last 20 comments - View All

CARTONPLAST

Buyer

Wed, 01 Dec 2021 16:27:21 +0000
Ladies and Gentlemen
May I say thank you for all your efforts and ideas!
It had been not easy to select the winners finally but nevertheless we had to make a decision!
All of your ideas helped and showed you are creative!
Thank you again and all the best!
Very best greetings :)

designitzsolt

Designer

Sat, 06 Nov 2021 15:13:52 +0000
Hi,
Please check my proposal and write a feedback when you have time :)
Thank you in advance , Best regards Zsolt

CARTONPLAST

Buyer

Fri, 05 Nov 2021 12:17:39 +0000
Hi Chaniago, just done 15 minutes ago :)

Chaniago

Designer

Fri, 05 Nov 2021 10:46:41 +0000
Hi....
Can you provide a review or feedback on design that I submitted, so I can change the design as soon as possible

Thankyou
Regards
Chaniago

CARTONPLAST

Buyer

Fri, 05 Nov 2021 10:41:51 +0000
Hi ZaiDMcAllister
Sure, we can do a Zoom-Meeting.
Can you send me an invite?
Greetings :)
Wed, 03 Nov 2021 21:06:37 +0000
Hi there,

I have seen your content and would love to have a go at providing a solution. Before I begin, would you be free for a quick Zoom call? I have a few questions about the application as well as the quantities you are looking to manufacture these in and want to be on the same page.
Tue, 02 Nov 2021 12:48:27 +0000
Thank you! I will try my best!

CARTONPLAST

Buyer

Tue, 02 Nov 2021 12:02:28 +0000
As Long as we can open the files, yes, you can.
Greetings :)
Tue, 02 Nov 2021 04:22:22 +0000
Can we make it in blender?

CARTONPLAST

Buyer

Sun, 31 Oct 2021 18:07:21 +0000
Hello Chaniago
Very good questions!
The material of the new TOP CAP has to be washable, re-usable, recyclable and food-safe. For sure plastic. We would prefer Polypropylene.
The dimension of the bottles is very difficult to answer as there are all kind of bottles and glass-containers possible. So this is not made for one specific but one TOP CAP to cover all!
Yes, for sure there is a potential budget per TOP CAP which was not mentioned as we not wanted to limit the ideas for now. Just for your information, the price should be less than 20,-- € per TOP CAP.
Thank you for your questions. If there are more, please let me know.
Greetings :)

Chaniago

Designer

Sat, 30 Oct 2021 08:18:06 +0000
Hi...Dear

This is a very interesting project and after reading and reviewing this project there are a few things I want to ask:
1. Can we change the material from the current one or do you have a replacement material reference from your customer? because this usually arises from customer complaints
2. Can you share the details of the dimensions of the bottles you produce?
3. Is the new design for this top cap focused on the budget? Or can you tell us how much the estimated budget is? Because the design will be greatly affected by the budget

Thankyou
Regards
Chaniago

CARTONPLAST

Buyer

Fri, 29 Oct 2021 06:56:39 +0000
sherifelsheikh
studio701
Pre-Paid and blind. Done!
Greetings :)

sherifelsheikh

Designer

Thu, 28 Oct 2021 13:28:11 +0000
Hello, Prepaid and blind please

CARTONPLAST

Buyer

Thu, 28 Oct 2021 07:16:53 +0000
Hi Bhavik Mistry
Thank you for all your comments.
You are correct, the TOP CAP is moved by an automatc pick and place to the glass containers and moved away while unloading from the palett again by an automized pick and place.
For your comment that the folding behaviour" will be the same for all TOP CAPs due to an automized handling, I'm not convinced especially regarding the Nylon straps.
Let me have look for the details and I'll come back to you later. Meanwhile, please have a look to the patents I added to the attachments as well.
Greetngs :)

Bhavik Mistry

Designer

Thu, 28 Oct 2021 04:28:39 +0000
Dear CARTONPLAST,

I would like to share few more points regarding your concern about flap degree,

1). As you can seen in the 3D model I had shared, I designed hinge in such a way that center of Gravity of the flap is right side of the axis of hinge , so it will open perfectly 90 degree without a drought.

2). Hinge design allows the side flap to completely touch with the glass bottles when shrink wrap so that it will not move during transportation.

Thanks,
Bhavik Mistry

Bhavik Mistry

Designer

Wed, 27 Oct 2021 07:27:48 +0000
Dear Sir/Ma'am,

Thanks for your valuable feedback,
1).
Given concept was based on some assumption,
When Top cap is lifted by Robotic arm/Any mechanism , it will remain parallel to the ground . I have designed hinge mechanism in such a way that their will be very less friction so that it will open due to its self weight.
(i tried to make the design simple and with less complicated components. we can use 90' spring if top cap will be operated in fully automation environment.)

2).
Sir, if it will be handle by robot than the nature of folding will remain the same for all the TOP CAP. on the other hand, if it will be handle by human we can incorporate STOPPER BOSS(Emboss Surface at bottom side. which height will be more than total folded strap to avoid leaning tower.)

Thanks!



CARTONPLAST

Buyer

Wed, 27 Oct 2021 06:52:13 +0000
Hello Bhavik Mistry
Thank you for submitting the idea. I do like the approach.
May I guideline a little and ask some questions:
How do you insure the side flaps will open up for 90° by gravity and do not end at 70°? This would cause to kick off bottles while the TOP CAP is positioned at the end of the palletizing.
How does the nylon straps fold when the TOP CAPs are stacked? If this folding is not controlled you will get a "leaning tower".
It would be very interesting as well to get some detailed information about the hinge you wanted to implement.
Greetings :)

CARTONPLAST

Buyer

Wed, 27 Oct 2021 06:35:21 +0000
Hi anshul
Basically I do agree for the reuseablilty of blister-packagings.
If I got you right you wanted to implement the glass-container-pattern for the palletized glass containers into the blister packaging.
Give me an idea, how many different pattern do you expect to be created?
Greetings :)

KND_design

Designer

Wed, 27 Oct 2021 04:41:01 +0000
Hello CARTONPLAST, Very interesting project thanks for hosting,
Regarding comment from studio701, Prepaid contest will attract top designers and combined everyone will submit unique concepts that you will not regret making contest prepaid otherwise less designers will take part. This because many contest holders don,t give results just take designs submitted after contest is over.

Bhavik Mistry

Designer

Wed, 27 Oct 2021 04:37:46 +0000
Hi, Cartonplast,
I have submitted my concept design for your review.
Thank you!

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