We are eager to share the success of our collaboration with Virginia Tech’s Packaging Systems and Design program. This capstone project marked the beginning of our commitment to giving back to the community by mentoring and sharing our industry expertise with the next generation of innovators.
During the 2024 spring semester, Virginia Tech students took on two pivotal projects with the support and guidance of PSI’s design team, gaining invaluable hands-on experience along the way. The first project focused on creating an all-paper cooler for the medical field while the second centered on redesigning the Veeder-Root probe packaging to better align with PSI’s capabilities. These collaborations not only demonstrated the students’ exceptional abilities but also produced innovative solutions to real-world challenges.
Project 1: All-Paper Cooler for the Medical Field
The first group of four students tackled the challenge of developing an all-paper cooler for the medical field. This eco-friendly solution aimed to transport temperature-sensitive medical supplies sustainably.
The objective of this project was to make a curb-side recyclable fiber-based cooler that has the same functionality as a 1-inch EPS cooler. This type of packaging would be used for medical products such as vaccines. The goal line of success would be to last below zero degrees Celsius for 36 hours in the ISTA 7E test using at most 5 kg of dry ice.
The primary challenge of this task was that fiber-based materials don’t have the same properties as EPS (Expanded Polystyrene). Although EPS offers excellent insulation, it has significant environmental drawbacks—namely, a large carbon footprint and the fact that it almost always ends up in landfills.
The students experimented with various materials and designs to ensure the cooler maintained necessary temperatures while minimizing environmental impact. The proposed solution came out to be a 32 C-flute 12”x12”x 12” full overlap outer box with an e-flute auto-lock bottom box to hold the vials in place and limit the amount of contact they have with the rest of the package and dry ice. Their project stands out as a remarkable blend of sustainability and functionality.
Project 2: Redesign of Veeder-Root Probe Packaging
The second group was tasked with improving the current packaging solution for Veeder-Root’s tank gauge probe. The design requirements specified the following:
- Eliminate polystyrene from the design
- The probe must slide into the box without restriction or obstruction
- The packaging must be producible at PSI on existing equipment
- Twelve packs must stack securely without tipping over
- The probe box glue flap must not have hard, sharp glue leakage
The group set a goal aimed at replacing the EPS (Expanded Polystyrene) foam to be more sustainable and maintain equal or greater durability.
The group’s final design uses a 44-ECT outer sleeve and 32-ECT insert made of corrugated board as the main structure component, supplemented by minimal amounts of polyethylene foam in the cap area where sensitive circuitry is contained. This combination strikes an optimal balance between protection and environmental impact. The corrugated structure offered the required rigidity to withstand moderate bending forces while also being easy to machine and assemble using PSI’s existing equipment.
Veeder-Root is now working towards incorporating the team’s sustainability-forward design changes into their standard materials.
The projects were chosen by the students based on their interests within the Packaging Systems and Design major. They were mentored by Dr. Bush and various other professors throughout the semester. The students also had the opportunity to collaborate with Ben and Daniel from PSI’ Design Team. This support was crucial in helping the students navigate their projects’ complexities, enriching their learning experiences and fostering professional growth.
The projects provided an opportunity to apply classroom knowledge to real-world challenges, preparing them for successful careers in the packaging industry.
We are proud of the achievements of these students and the positive impact of our collaboration with Virginia Tech. Their dedication and innovation highlight the bright future of the packaging industry.