David Winters

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University of Nottingham > Engineering > Departments > Mechanical, Materials and Manufacturing Engineering > PDM End of year show 2023 > MEng students > David Winters

A reusable packaging system to cut down on waste and reduce the strain on the planet.

This major project is the culmination of 5 years of both university and industry-based learning, yet the roots of my passion for design can be traced back to the first time I stepped into a D&T workshop at school some 15 years ago!

I chose PDM at Nottingham for its ability to equip me with all the tools and techniques to apply myself across a diverse spectrum of design projects, both from a product and graphic perspective. The uniqueness of PDM comesfrom how the engineering side of the degree has taught me to understand materials, manufacture, markets and viability. The high-fidelity level of realism applied to projects through work on full product costings, FEA validation or creating our own immersive branding has been one of the most enjoyable aspects of my time at Nottingham.

My passion for future-focused, sustainable design saw me named as a finalist in the national 2021 Undergraduate of the Year Award for Sustainable Thinking. My industrial year in Müller UK & Ireland's Packaging department enabled me to put many of my problem-solving orientated skills into practice, honing them further within a professional FMCG working environment. Applying myself to sustainability led design innovation projects in industry only reaffirmed my passion for design and its power in both forging our future and improving consumer lives.

My major project has allowed me to utilise the skills nurtured over my career, in a context that tackled both sustainability and user-centred design. Whilst the core (no pun intended) of the project looked at creating a sustainable alternative to single use packaging, the rationale of looking at the whole reuse system was so that a product family could be implemented that streamlined user interaction to a level not seen on current industry models.

I am excited for what the future holds in industry, but will always look back upon these past five years with great fondness and pride at the collaborative achievement of our cohort.

David Winters, MEng Product Design and Manufacture

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CORE Reusable Packaging System

Single use packaging creates 36% of Europe’s solid municipal waste annually - with only 10% of this recycled correctly. Societal norms must change rapidly to reduce the strain this waste has on our planet. Industries are increasingly looking towards reusable packaging as a potential solution.

The UK food industry has seen numerous reuse trials fail to gather traction over the past few years. There is a need for a ‘lighthouse project’ that can become engrained in the day-to-day routines by streamlining each user-interactable stage of the reuse chain (delivery, use, storage, return, courier collection).

This is where my design solution comes in, CORE. This product family is pivoted to the vegetarian/vegan market who utilise an on-trend recipe box delivery service. The packaging, Stax, is delivered in a storage crate, Stow. Empty articles are returned to the Stow which is used to transport the packaging to a community smart locker, Store - where the crate is deposited ready to be collected for cleaning and refilling. Further product information can be found below:

‘Stax’ Packaging: Five initial articles have been designed for diverse SKU containment. Pack bodies are made from 304 Stainless Steel, selected for its durability, ease of sterilisation and ability to be recycled into food grade use recyclate post-life. These are matched to a food safe TPU lid. The material’s flexibility enables inclusive opening for all, whilst its highly inert, easily sterilised, temperature resistant properties maintain hygiene. A leak-proof, recyclable single use foil seal is applied for further peace of mind. Each article should survive >100 reuse cycles.

‘Stow’ Crate: There are two elements of the Stow, a rigid PP inner crate (owned by the retailer) and a hemp outer bag (owned by the consumer). The inner crate is delivered filled by the retailer or courier and is then placed into the apparel-type outer bag within the consumer’s home. Packaging designs were carefully considered alongside the Stow crate to maximise storage efficiency (each crate can hold 4-5 family sized meal kits). The inner crate can fit within typical 60x40cm delivery van bale arm crates, includes a carry rim for handling support and is equipped with a waterproof RFID label for supply chain tracking.

‘Store’ Locker: Constructed from a powder coated, projection welded steel frame - the lockers are placed in ‘hubs’ on community car parks where both consumer and courier can drive right up to the double-sided design for easy access. Each locker door is equipped with an RFID lock, opened by a corresponding RFID label on the Stow crate. The backpack type fabric bag means the user can simply hold the crate against the lock interface to open the door, place the inner crate inside, close and go! The interior angled shelves and conveyor rollers support crate placement by sliding up to 12 crates towards the rear door, hence simplifying removals for the courier. Neutral powder coatings allow retailer branding to shine, for ease of user identification.