DESIGN LOG - BIOPLASTIC FOOD CONTAINER SET by Wannable Chanpi

CHAN CHAK WAH 200130786

DESIGN LOG BIOPLASTIC FOOD CONTAINER SET

BA (Hons) in Product Design Faculty of Design and Environment Technological and Higher Education Institute of Hong Kong

PART 1: RESEARCH LOG 1

u Background

u Introduction

u Project Summary

T E

u Mind Map u Food Waste Problem

u Findings

u Market Research Analysis u S.E.T Factor u Political Factor u Summary u Market Segmentation u Content Scenario u Design Scenario u Persona

u Existing Competitors u Matrix’s Chart u Positioning Map u Opportunity Gap

PART 2: PROPOSAL 2

u Time Schedule

u Project Brief

N T E N T

PART 3: MATERIAL TESTING 3

u Records 2

u Records 1

u Introduction

T E T

Molding

u Double Shot Injection

PART 4: IDEATION 4

u Concept Sketches

u Thumbnails

u Mood Boards

u Form Exploration

u Development Sketches

u Summary

u Foam Modelling u Model Testing u Brand Plan u Dimension Diagrams u Exploded Diagrams u Product Renderings u Coloration u Presentation Boards u Presentation Videos

u Reference

RESEARCH LOG

PROJECT SUMMARY The project's process begins with an assessment of the issues that need to be addressed, including food waste and disposable plastic container and tableware waste. Then conduct market research, analyze target users and market segments to explore the design opportunities. For the potential market, the design is mainly aimed at the general public, especially those who also purchase takeaways. By partnership with environmental organizations such as GREEN@COMMUNITIES, a range of bioplastic recycling mechanisms can be implemented. From the procedures of biodegradable material testing, the feasibility of using eggshells, calcium alginate, gelatin, coffee bean shell, shrimp shell, PLA and other materials for bioplastics with different formulations is verified. Afterwards, the properties of the different samples were analyzed by material testing. The purpose of the test is to find a new decomposable, biodegradable and reusable hard material to solve the current problem of food waste. Based on research and testing result, proposing design concepts in order to address user pain points, testing of concepts and presenting final design in a clear manner. After extensive material experiments, the best result was obtained when combining PLA and eggshells. From different percentage of eggshells and PLA, the optimal content of eggshells in PLA is about 10% to 20%, which produced materials that were more stable, harder, smoother and more water resistance than the rest. Since PLA could be 3D printed, eggshells-PLA could potentially be converted to 3D printable form. Many applications could be explored based on the physical properties. Therefore, the final design will be food container set made of eggshells and PLA. The purpose of the design is to change people's habits when buying takeaways, and to encourage the use reusable containers. Hence, tough bioplastic containers can play an important role in sustainability.

INTRODUCTION Food waste problem will be assessed from this section, to identify opportunities and challenges for food waste recycling, with the aim of exploring opportunities for sustainable design concepts and design directions.

BACKGROUND

MIND MAP

FOOD WASTE PROBLEM Food waste is a global issue. According to statistics from the Food and Agriculture Organization of the United Nations, approximately one-third of the world's food (1.3 billion tons) is wasted every year. The influence of food waste has caused serious problems to the environment, economy and society, such as environmental pollution, market inefficiency and social inequality. In Hong Kong, citizens discard more than 3 600 metric tons of food waste every day, which can fill about 1.4 standard swimming pools, of which nearly 70% is household food waste, and the remaining 30% comes from industry and commerce. At present, most of Hong Kong's food waste is discarded in landfills along with other solid waste. This method is not sustainable because it will deplete the limited landfills.

IMPACT OF FOOD WASTE ON THE ENVIRONMENT It goes without saying that the later food is wasted along the chain, the greater its environmental impact, because then we also have to take into consideration the energy and natural resources expended in processing, transporting, storing, and cooking it. Food waste that ends up in landfills produces a large amount of methane – a more powerful greenhouse gas than even CO2. Excess amounts

greenhouse

gases

such

methane,

CO2

and

chloroflurocarbons absorb infrared radiation and heat up the earth’s atmosphere, causing global warming and climate change.

FINDINGS

50 questionnaires surveyed the user's recyclable product food waste. According to feedback from Hong Kong residents over the age of 18, the ratio of male to female is about half. The aim is to find out if there are more opportunities in the recyclable food waste from food waste structure. Find out if there are more innovative thinking solutions beyond the usual food waste disposal methods. Among the recyclable food waste, grains (bread, rice, flour) and others (coffee grounds, tea grounds, expired foods, cakes, or desserts)

Results

accounted for the largest proportion during breakfast, with 29 people per person, accounting for about 60%. Vegetables and fruits (vegetable leaves and stems, fruit peels and cores) are the most during lunch time, accounting for 70%, followed by meat and poultry (leftover meat, offal. Small bones, and eggshells), accounting for nearly 50%. At the end of dinner time, the most food waste left by most people is meat and poultry (leftover meat, offal. Small bones, and eggshells). Nearly 80% of the population is 38 people.

MARKET RESEARCH ANALYSIS

S. E. T FACTOR

SOCIAL

USERS’ ATTITUDES ON RECYCLING FOOD WASTE

Asian countries have different eating habits

Fast-paced lifestyle has also exacerbated the

from European and American countries,

food waste problem in Hong Kong. As a

and the proportion of solid waste formed in

world-recognized

kitchen waste is higher. Organic solid waste

commercial center, Hong Kong citizens

with a high content of kitchen waste usually

have adopted a fast-paced lifestyle and

contains a lot of water, and its calorific value

improved efficiency. Fast food as meals and

is usually lower than 5000 kJ/kg, which is

rarely

difficult to achieve. incinerated.

makes food waste such a small thing that

cook

world

themselves.

financial

and

Fast-paced life

most people don't care how much food they waste each day. Therefore, the food Also,

serving

food

for

meal

symbolizes wealth and generosity. Therefore,

waste recovery rate in Hong Kong is very low.

Hong Kong people order more food than they can afford. These two factors will be causing more food waste.

DİSPOSABLE FOOD CONTAİNERS AND TABLEWARE ISSUE DERİVED THE USE OF PLASTIC TABLEWARE HAS SURGED

During the epidemic, many citizens and businesses changed their dining methods in order to reduce the risk of virus transmission. Under the government's measures of "restricting gatherings" and "banning dine-in", many citizens have turned to takeaway services, which has become the new normal during the anti-epidemic period. However, the amount of plastic waste has skyrocketed.

increase

takeaway

food

during

the

pandemic is driving Hong Kong's use of more than 100 million single-use plastic items per week during the pandemic, a study found. From plastic tableware, food containers, bags and straws, the amount of disposable tableware consumed by the city's residents more than doubled from 2019 figures. Research

released

Hong

Kong-based

environmental charity Greeners Action shows the staggering amount of waste generated by the increase in takeaway food during the pandemic. Based on a survey conducted in 2020, the study estimated that the number of takeout orders in the city surged 55% to 21.1 million a week from 13.5 million before the pandemic began. More than 52% of respondents said they ordered more takeaway orders in lieu of dine-in due to ongoing social distancing restrictions, the survey found that household consumption of plastic items has increased dramatically, with single-use plastic

tableware

consumption

exceedingly

weekly Five items jumped from 10% in 2019 to 30% in 2020. On the other hand, the use of plastic containers rose from 12% to 45%. Overall,

the

number

single-use

plastic

tableware (including straws, containers, cutlery and bags) reached 101.8 million pieces per week, more than doubling from the previous year.

ECONOMIC

IMPROPER CONSUMPTION BEHAVIOR

The current global food crisis is the product of, or even built upon, an extremely

wasteful

production facilitated

and by

process

consumption,

greedy

global

economic system that undervalues food prices (leading to distortions in consumption) and its components. In relatively affluent societies, the phenomenon closely

food to

waste

consumption

behavior. Consumers over-buying and hoarding lead to expired food; merchants discard food due to over-stocking, damaged product packaging,

poor

appearance

improper handling of ingredients, etc., are the main causes of food waste.

Photo source: FAO(2018)/ https://www.facebook.com/UNFAO/photos/each-year-13-of-allfood-produced-for-human-consumption-is-lost-or-wasted-around/10155070103378586/

The FAO estimates that every year after

The Asia-Pacific region accounts for 54% of

harvest or manufacture, one-third of the

the world's total production, 53% of the

world's food production is lost or wasted in

world's cereal production, and 70% of the

shops, homes and food services. Converted

world's fish supply. If APEC economies can

to economic value, that equates to a

achieve the goal of reducing food waste by

production cost of $750 billion, or a retail

50% by 2030, it will make a huge contribution

price of around $1 trillion. If nature asked

humans to pay for food waste disposal, it

promotion, capital investment, innovation

could collect at least $700 billion a year.

momentum, and industry cooperation can it

Because this wasted food leads to unseen

be possible to improve the situation of food

greenhouse gas emissions, climate change

waste from the source.

the

world.

Only

with

government

damage, water scarcity, forest and land erosion, biodiversity loss, and higher food prices due to reduced supplies.

TECHNOLOGY

PRODUCTİON

California-based Apeel has introduced a new approach to reducing food waste by using a plant protection coating to protect produce and make it last longer. This layer is invisible and edible, so it is safe to eat.

PROCESSİNG

InStock is a Dutch restaurant dedicated to serving oddly shaped food for people who don't care about looks. It rescues food from producers,

growers

and

packaging

companies, and provides a second chance for seemingly unreliable products.

CONSUMER

Consumers can benefit from using the Fridgely app, which tracks when certain foods expire and alerts consumers so they can eat them before they spoil.

TRANSFORMATION

Dr. Alex Yip from the Department of Chemical and Process Engineering at the University of California is leading a study on the transformation of food waste with the ultimate goal of producing highvalue products from food waste, and a proof-of-concept has been completed showing that this is feasible. The project's goal is to extract three key chemical components from food waste, including polylactic acid (PLA) and the organic compound 5-HMF. If this innovative project is successful, there will be new uses for food waste. Bioplastics produced from food waste will be 100% recyclable or fully biodegradable and can be used in products.

WHAT IS PLA?

PLA

PLA is not plastic, PLA is also known as polylactic acid, unlike traditional plastics, it is made from plant starch, which also creates characteristics

that can be decomposed by bio-utilization. Most of

the

traditional

plastics

come

from

the

distillation polymerization of non-renewable oil and natural gas. Plastics derived from biomass (such as PLA) are called “bioplastics”。

DIFFERENCE BETWEEN PLA AND TRADITIONAL PLASTICS

Source: Mark (2022)/ https://www.ecodinnerset.com/products/recycled-bpa-free-eco-friendly-pla-food-storage-containers/

Source: www.idayin.net, (2019)/ http://www.idayin.net/zhishi/536.html.

PLA

has

excellent

biodegradability and can be

completely

degraded

microorganisms in the soil within 180 days after disposal to generate CO2 and water, which does not pollute the environment.

The plastic classification of polylactic acid is 7. There are variety disposal methods for waste

polylactic

products,

such

decomposition, and incineration.

acid natural

composting,

High

safety,

can

package

food, PLA can contact the skin for

long

time,

high

antibacterial activity, can be used to package fruit and fresh food.

It meets the requirements of environmental protection, has good

transparency,

good

mechanical strength, strong tensile property and ductility, and can be processed by all plastic processing methods.

PLA has many common uses, including

PLA is made by injection molding, casting,

medical and food applications. It is also

or spinning, and can also be used as

widely used as a 3D printing material for

decomposable packaging, film, or in cups

desktop fuse manufacturing 3D printers. PLA

and bags. Used in compost bags, food

is popular in 3D printing because it can be

packaging,

easily sanded, painted or post-processed. A

packaging. As a fiber or nonwoven, PLA is

user-friendly material, this plastic operates at

used in upholstery, disposable clothing,

low extrusion temperatures and does not

feminine hygiene products and diapers.

disposable

tableware,

require heated beds, printer chambers or reinforced nozzles.

TRANSPORTATION

AGRICULTURE

ELECTRIC

APPLICATIN OF POLYLACTIC ACID (PLA) TEXTILE

PACKAGING

BIOMEDICAL

bulk

POLITICAL

EFFECTİVENESS OF FOOD WASTE TREATMENT İN HONG KONG

SUSTAINABLE FOOD WASTE MANAGEMENT SYSTEM

Disposing of food waste to landfills is unsustainable because it will exhaust the limited landfill space. In order to solve the food waste problem in Hong Kong, other methods have been adopted apart from landfills, but not very effective. The processing capacity of the Government Recycling Center is very low, and it is not enough to cope with the daily food waste generated by the people of Hong Kong. If there is no perfect food waste disposal method, a large amount of food waste and other waste will be dumped into the landfill every day, and the landfill will become full.

“FUNDING SCHEME FOR FOOD WASTE RECYCLING”

Environment Bureau (ENB) launched the “Funding Scheme for Food Waste Recycling” in Housing Estates from 2011 to 2019. The scheme uses the Environment and Conservation Fund (ECF) to subsidize housing estates to install food waste treatment devices. Relevant education and promotion activities are expected to allow residents to actively participate and increase their awareness of food waste reduction and recycling.

Low participation rate

Lack of overall planning

The number of residents in public housing

After the end of the project funding period,

estates participating in the food waste

some of the participating housing estates

recovery pilot program is small. Among the

will only receive part of the rent and

67 600 households in the 14 public housing

purchase fee subsidized by the

estates, the Housing Department only

Environmental Protection Fund, and they

invited 52 000 households (77%) to

will have to afford the operating expenses

participate in the food waste recovery pilot

themselves. Some housing estates had no

program. Among the 52 000 households,

choice but to terminate the food waste

only 6.2% participated in the plan.

recycling scheme after participating in the project for two years because they were

Insufficient space and odor nuisance

unable to cope with the related expenses.

It was concerned that housing estates may

The plan does not have a proper framework

not be suitable for food waste recycling

and the procurement process is very

since the production of compost will cause

difficult. For example, the government

unpleasant odors if controlled or poorly

provided more than 20 contractors, but four

ventilated, housing estate designs may not

are repeated, and some do not engage in

have suitable and sufficient space. Inherent

residential business. Participated in the

restrictions are very large. In addition, each

(Environmental Protection Agency) test, the

housing estate has only one composting

bacterial content test failed the test. In

machine is subsidized, and it can only

addition, the department has not yet

recycle up to 100 kilograms per day, which is

arranged the method of fertilizer use as a

low cost-effective.

guideline for the use of fertilizer, how to deal with the remaining fertilizer.

The on-site recycling model is limited by the space of individual housing estates. This will involve higher labor and operating costs. Therefore, the on-site recycling model and its continued implementation are more difficult to obtain general support from housing estate residents. In contrast, the offsite recycling model is more cost-effective. The extensive and continuous operation of this model among residents is more reasonable.

SUMMARY

SUMMARY Social Factor •

Different eating habits as organic solid waste with high content of Aisan food waste usually contains a lot of water and is difficult to incinerate.

•

People ordered more food than they could afford.

•

Fast-paced lifestyle exacerbates food waste problem in Hong Kong.

•

Food delivery service has become the new normal during the anti-epidemic period. The number of disposable food containers and tableware has skyrocketed.

Opportunity •

Designed to reduce moisture in food waste, drying it out, using sawdust etc to absorb excess moisture.

•

Design can measure and calculate the quantity, demand and other data of food to help people better plan food purchases.

•

Design could make Hong Kong people more aware of wasted food.

•

Designed to match today's delivery service.

•

Design can encourage and change human awareness of using eco-friendly food containers and tableware.

Economic •

Improper consumption behavior.

•

Consumers over-buying.

•

Hoarding lead to expired food.

•

Merchants discard food due to over-stocking.

•

Damaged product packaging.

•

Poor appearance or improper handling of ingredients.

•

Food waste leads to unseen greenhouse gas emissions, climate change damage, water scarcity, forest and land erosion, biodiversity loss, and higher food prices due to reduced supplies.

Opportunity •

Design can prevent consumers from overbuying and creating unnecessary food waste.

•

The design can better extend the expiration date of food and store food properly.

•

Design can take advantage of poor looking or mishandling ingredients.

SUMMARY Technology

Opportunity

•

Apeel plant protection coating to protect produce and make it last longer.

•

The design can work with an app to track the expiry date of food.

•

Fridgely app, which tracks when certain foods expire.

•

PLA, made from plant starch, creates bioavailable and decomposable properties.

Designs can utilize PLA materials for various applications.

•

Design can study whether PLA can achieve 3D printing.

•

High safety, can package food, PLA can contact the skin for a long time, high antibacterial activity, can be used to package fruit and fresh food.

•

PLA has many common uses, including medical and food applications.

•

It is also widely used as a 3D printing material for desktop fuse manufacturing 3D printers.

Political

Opportunity

•

Low processing capacity at government recycling centres

•

Design can reflect and improve food waste recycling.

•

Food waste recycling project:

•

Design can provide incentives to increase resident participation, use enclosed designs to avoid odors, etc.

•

Low participation rate

•

Insufficient space and odor nuisance

•

Lack of overall planning

From the preliminary research stage, the

environmental

protection

and

sustainable food waste management policies that have been implemented are still insufficient. While retaining policy

standards

different

design

explore

and

solutions

and

opportunities

develop

from

advantages,

also

sustainable designer's

perspective to meet market demands

and

current

government

environmental policies.

MARKET SEGMENTATION

ENRIVOMENTALISTS

GEOGRAPHIC

PSYCHOGRAPHIC

Region: Asia Location: Hong Kong

Lifestyle: Minimalist mode, Healthy Attitude: Developed a habit of reducing waste, eliminate waste, reduce waste from the source

MARKET SEGMENTATION

DEMOGRAPHIC

BEHAVIORAL

Age: 20 to 40

Using Rate: Working days, Sometimes

Gender: / Occasions: Outdoor, Income: Middle Class

Restaurant, Office

CONTENT SCENARIO

Tiffany is an environmentalist and eco-minimalist. She has good environmental awareness. She tries to avoid and reduce unnecessary waste at the source. Therefore, every time she disposes of unused waste, she will think twice about whether it is worth using. While Tiffany cooks for herself most of the time, sometimes she chooses to purchase takeaway when she's busy. At this time, she will bring her own environmentally friendly food container and tableware. She has previously used food containers such as stainless steel, plastic, glass and silicone. Nonetheless, these food containers have their own inconveniences and cons. Glass food containers are heavy and break easily. PP food containers tend to age and wear out over time. Silicone food containers tend to get dusty, leaving food coloring and odorous residues behind. Stainless steel food containers generally cannot be microwaved. Furthermore, when the service life of food containers is exhausted,

so-called

reusable

eco-friendly

food

container

becomes

environmentally harmful waste.

DESIGN SCENARIO

Eco-friendly lunch boxes and cutlery prepared by Tiffany are reusable and made from 100% natural materials. Even after the life of the product is used up, there is no need to worry about the harm to nature when recycling, because the material is pure natural and can be decomposed naturally. In addition, the lunch box is also very easy to use, easy to store, clean, waterproof and microwaveable.

PERSONA

MARKET SEGMENTATION 2

Young People/ Workers

GEOGRAPHIC

PSYCHOGRAPHIC

Region: Asia Location: Hong Kong

Lifestyle: Rapid pace of life, spends a lot of time socially, always purchasing takeaway Attitude: Active in life, receptive to innovative things

MARKET SEGMENTATION

DEMOGRAPHIC

BEHAVIORAL

Age: 15 to 30

Using Rate: Working days, Sometimes

Gender: / Occasions: Outdoor, Income: Low Class to

Restaurant, Office

Middle Class

CONTENT SCENARIO

Tom is a young office worker who has just entered the society. In addition to a fastpaced life, he pursues efficiency and saves time. Also like to buy some innovative tools and techniques with colleagues. He loves following trends and being active on social media and loves social events. Tom's eating habit is generally that most of his three meals are purchasing takeaway or ordered takeaway to the office. Large quantities of disposable containers and tableware are produced each time. Furthermore, because of the large amount of food each takeaway, it's easy to leave a lot of food.

DESIGN SCENARIO

Tom experimented with new food containers, increasing environmental awareness and focusing more on sustainability. At first, he was just attracted by this innovative eco-friendly material technology and design and got the promotion of this product on different social media, so he bought this food container. Later, he was not only encouraged to use his own eco-friendly lunch boxes and cutlery, but also influenced his social circle.

PERSONA 2

EXISTING COMPETITORS

1. Bagasse Take-out Container Color: White/ Shape: Rectangle clamshell/ Materials: Plant Fiber (Sugarcane pulp/Bagasse) Pros Material features:

✓ Sugarcane pulp/Bagasse has the necessary resistance to humidity, as well as the airtightness required to isolate food from external agents. ✓ Can replace polystyrene foam. It has excellent thermal properties and does not absorb condensate like plastic, so food can stay warm and crispy. ✓ 100℃ Water &120℃ oil resistant, without leakage ✓ Microwavable and freezer-safe ✓ As strong as foam, or even stronger than foam. ✓ Incredibly light Eco-Friendly Design:

✓ Bagasse products normally biodegrade within 90 days; plastics will take up to 400 years to degrade and Styrofoam never degrades. The rate of decomposition depends on the composting conditions – the temperature, turnover rate, moisture etc. Generally, they will biodegrade much faster if they are broken into smaller pieces. ✓ This sugarcane / bagasse item takes up less storage space than other disposable alternatives, and it can hold heavier foods than either paper or Styrofoam. Plus, since it requires much less energy to produce, it saves on both energy and resources. Perforated and Secure Lid:

✓ With an easy-to-close perforated lid, this container quickly goes from a convenient carrier to a serving dish in no time at all. ✓ To prevent spillage, this disposable container boasts a secure lip along its edge. This added protection helps contain the contents by creating a tighter seal between the lid and container than traditional foam or cardboard takeout boxes.

Cons

✗ Uncoated products may absorb grease and other food. ✗ When merchants pack for takeout and customer received the takeaway containers, each food container is independent and therefore needs to be stacked for taken away or put in a paper bag or plastic bag. Thus, a more piece of packaging will be produced. ✗ The appearance is like the traditional foam packaging box as the clamshell shape. The aesthetics is not attractive. ✗ There is no relevant environmental protection education and promotion printed on the packaging, so the concept of biodegradation cannot be promoted to others, and their awareness cannot be raised. ✗ The cost is more expensive than ordinary plastic tableware.

2. Poly-coated Kraft Paper Containers Color: Kraft/ Shape: Square box/ Material: Paper

Pros Material features:

✓ Collapsible design takes up less storage space. ✓ Conserves heat ✓ Heat lamp-tolerant and microwave-safe options available. ✓ Added durability from a poly coating to allow you to package a wider variety of foods in both hot and cold applications. ✓ Leak- and grease-resistant, making them strong enough to hold up to sauces, gravies, and oils. ✓ Breathable to let steam and moisture out to prevent foods from getting soggy. ✓ Heat lamp-tolerant and microwave-safe options available. Environmental advantages:

✓ Natural kraft color does not contain toxic dyes ✓ Recyclable and typically contains recycled content ✓ Environmentally friendly alternative to foam or plastic ✓ It retains its natural color and texture, so no additional bleaching steps are required. This saves money because it is necessary to reduce material handling and keep chemicals away from the environment. Tab Lock Top:

✓ With four flaps and a tab lock on top, this microwavable container ensures that your patrons' food stays fresh and at the perfect temperature, and that no spills or messes occur during transportation. Printing and design:

✓ Cardboard can be printed on easily making it perfect for marketing, branding, and promotional purposes.

Cons

✗ Compartments not available in paper containers. When some food set requires sauces and contain different foods, they are easily mixed or need more containers to pack. ✗ Not able to hold as much weight as plastic and so cannot be stacked as easily without breakage. Also, it may bend or fold when used with heavy food. ✗ Much less durable than plastic and can be susceptible to mould, fire, and water damages due to weather. ✗ Bigger footprint during transportation: As plastic is lighter and thinner than kraft paper alternatives, the logistics footprint of paper-based material is higher. ✗ Poly coating makes the material harder to recycle. ✗ May not be sourced from sustainably managed forests.

3. PLA Plastic Containers Color: Clear/ Shape: Square/ Material: PLA Plastic

Pros Material features:

ü PLA (polylactic acid) plastic is a thermoplastic typically made from the sugars in corn, cassava, or sugarcane. ü Suitable for both hot and cold applications. Tolerate temperatures from 40 to 105 degrees Fahrenheit, making it great for both cold and hot foods. ü BPA-free Environmental advantages:

ü Compostable and environmentally friendly. These plants are domestically grown and annually renewable, making this container an excellent addition to your operation's sustainability program. ü PLA is compostable. When PLA is Incinerated, it emits fewer toxic fumes than oil-based plastics. Food Contamination of food packaging is not a problem, unlike with plastic recycling. ü PLA melts more easily because it has a lower melting point than many fossil-based plastics. It’s easy to work with PLA and it requires less energy to transform. ü Compared with traditional plastics, the carbon footprint is smaller. Crystal Clear:

ü The PLA container boasts a crystal-clear design that really lets the bright colors of your fresh fruits and vegetables pop. Separate Compartments:

ü Perfect for separating equal quantities of food.

Cons

✗ PLA has a higher permeability than other plastics. Moisture and oxygen will go through it more easily than other plastics. This will result in faster food spoilage. PLA is not recommended for long-term food storage applications. ✗ Low melting point makes PLA unsuitable for high temperature applications. PLA may even show signs of getting soft or deforming on a hot summer day. ✗ PLA is not the hardest or toughest plastic. PLA is not suitable for applications where toughness and impact resistance are critical. ✗ As it is chemically different, it must be properly recycled separate from traditional plastics. ✗ Only compostable under industrial composting conditions. It must be kept separate when it's recycled. Failing to do so results in contamination of the recycling stream. It's critical that it's transported to a composting facility instead of a recycling one.

4. Reusable Polypropylene Containers Color: Jade green/ Shape: Square clamshell/ Material: Polypropylene

Pros Material features:

ü Microwave-safe and dishwasher-safe ü Durable, break-resistant, and leak-resistant design Environmental advantages:

ü Polypropylene is more environmentally friendly than some other plastics. It's recyclable and doesn't release as many toxins as plastics such as PVC. It also breaks down more quickly, taking just 20-30 years compared to over 500 years for some other plastics. ü A financially-savvy, environmentally friendly alternative to disposable foam takeout containers. ü Reusable that each container can be used for up to 1000 uses ü Recyclable at the end of their service life ü Just as many people buy reusable grocery totes, an environmentally conscious customer might wish to purchase one to take home and bring back for refilling. Reward mechanism:

ü Perfect for cafeterias, caterers, colleges, hotel room service. ü Great for restaurants looking to implement a rewards program for loyal, conscious consumers. For example, customers can purchase a container upfront and with every time they exchange their used container for a clean one, they receive a discount on their meal.

Cons

✗ Not biodegradable ✗ Not a convenient enough substitute ✗ Not a cost-effective option for businesses in more tourist-central locations or locations that mainly serve guests that aren’t likely to return frequently. ✗ Polypropylene has limited use in high temperatures as it suffers from chain degradation which can lead to oxidization. ✗ Susceptible to UV degradation. Also, it has poor resistance to chlorinated solvents and aromatics. ✗ Polypropylene is extremely flammable and will melt when exposed to heat.

5. PrepNaturals Glass Containers Color: Transparent/ Shape: Rectangle/ Material: Glass, Plastic

Pros Material features:

ü Plastic free. ü Nontoxic - Made almost entirely of sand. ü Microwave safe. ü Refrigerator and freezer safe. ü Dishwasher safe. ü Oven safe (though lids made of different materials may not be). ü Non-porous surface ü Easy to clean and won't absorb or hide bacteria. ü Does not absorb taste, smell or stains from food. ü Does not react with acidic foods (no metallic taste). Environmental advantages:

ü The production and disposal of plastic presents many environmental concerns. Once you buy a glass storage container, you can use it almost indefinitely. Broken glass containers can be recycled. Recycling glass is cost-effective, and the process does not compromise glass quality. ü Eco-friendly and recyclable. Design Features:

ü Smartestlock locking lid technology locks food in safe, leak-free storage with an airtight seal. ü The convenient, multi-compartment bento design. ü Tight-clamping, watertight lids.

Cons

✗ Heavier than plastic. ✗ Fragile and needs to be handled safely, especially when traveling. ✗ The lid can only be washed in the dishwasher. ✗ The lid should be removed when heating in the microwave ✗ Care needs to be taken to go from hot to cold too quickly as the soda lime glass may crack. ✗ Glass containers are generally more expensive than plastic containers. ✗ There is a small gap between the edge of the separator and the bottom of the lid. While nothing will leak out of the container, food juices can mix. ✗ The lid is plastic. However, the lid's food-grade silicone seal limits plastic-food contact.

6. Collapse-it Silicone Food Storage Containers Sampler Pack Color: With Colors/ Shape: Round shape collapsible lunch box/ Material: Silicone

Pros Material features:

ü Plastic free. ü Non-toxic ü Made of silicon (sand), oxygen, carbon and hydrogen. ü Microwave and oven safe. Silicone does not melt, leach or expel chemicals when heating food. ü Refrigerator and freezer safe. ü Dishwasher safe. ü Unbreakable, soft and flexible - perfect for kids. ü Lightweight and easy to carry. ü Does not react with acidic foods. Environmental advantages:

ü Recyclable Design Features:

ü Soft food grade silicone for container and lid. Hence, zero plastic problems. ü Will not crack, leach or melt. ü Steam vents allow you to turn on food heating at the top without splashing. ü The easy-close lid creates an airtight, leak-proof seal, perfect for on-the-go use. ü Just press and the empty container shrinks to 50% of its original size.

Cons

ü Poor quality silicones may contain fillers. ü Although recyclable, it is difficult to find recycling centers that can handle silicone. ü It can sometimes absorb the smell and taste of food or soap. ü Darker colored containers seem to get hard water stains when washed. However, it doesn't affect performance at all. ü Silicone is not the most environmentally friendly material on the market. ü The production of silicones uses hydrocarbons derived from petroleum, which is not sustainable.

7. Stainless Steel Food Container Color: Metallic / Shape: Rectangle/ Material: Stainless Steel, LFGB silicone

Pros Material features:

ü Plastic free. ü Unbreakable yet lightweight - great for kids and travel ü Nontoxic - Made of Iron, Carbon, Nickel and Chromium. ü Refrigerator and freezer safe. ü Dishwasher safe. ü Oven safe. ü Non-porous surface ü Easy to clean and does not hide bacteria ü Eco-friendly and recyclable. ü Will not rust, stain or absorb food tastes, smells and smells. Years as new. Environmental advantages:

ü Stainless steel is a very environmentally friendly material as it is 100% recyclable. ü Production produces no toxic runoff. Design Features:

ü The set includes a large 24-ounce container for sandwiches, salads, and more. Also, a small 1.5 oz container for seasoning or seasoning. ü Between the 18/8 stainless steel and silicone lid, this combo is the perfect travel kit. The soft, child-safe lid won't leak.

Cons

✗ Not microwave safe. ✗ Nickel or chromium can be leached into your food. (It's harmless to most people, unless you're allergic.) ✗ If the steel is not polished, it can give acidic foods a metallic taste. ✗ Stainless Steel Appliances Tend to be More Expensive. ✗ They May Require Frequent Cleaning.

8. Le Creuset Stoneware Canister with Wood Lid Color: White/ Shape: Cylinder/ Material: Ceramic, Silicone Seal

Pros Material features:

ü Plastic free. ü Nontoxic. ü Microwave and oven safe. ü Refrigerator and freezer safe. ü Dishwasher safe. ü Does not absorb the taste or smell of food. ü Does not react with acidic foods. Environmental advantages:

•

The mineral bodies in ceramic clay are abundant and sourced from the earth. They create products that, when fired, can last a lifetime or longer. Both natural and foodsafe, ceramic dinnerware is significantly more sustainable than plastics which can actually leach toxins into the food we eat!

Design Features:

ü Dense stoneware blocks moisture absorption to prevent cracking, crazing and rippling ü Silicone gasket seal keeps contents fresh ü Impermeable exterior enamel resists stains and scratches from metal utensils ü Nearly-nonstick glazed interior easily releases foods for quick cleanup ü Stoneware Canister is Dishwasher-safe. Hand wash wood lid.

Cons

✗ A bit heavy, like glass. ✗ The jar will crack if dropped, so be careful. Also, wooden lids are not microwave safe. The intense heat and moisture from reheating food can ruin the topping. ✗ Fragile - needs to be handled safely, especially when traveling.

9. Cocoa Shell Recycled Lunch Box Color: Cocoa Shell color/ Shape: Layer-by-layer Cylinder Design/ Material: Cocoa shell

Pros Material features:

ü Cocoa waste made of biocomposites which is heat-resistant, lightweight, recyclable and insulated. ü The mycelium material is used as the inner layer of the insulation bag, while the outer layer uses a high temperature resistant biodegradable environmental protection material "Nuatan". This material is made of corn starch, sugar, and waste cooking oil. ü The bag cover is made of pineapple fiber imitation leather material. ü The handle is also made of special natural rubber. ü In addition, to prevent food and sauces from overflowing during transportation, environmentally friendly plastic with algae as the main material is made of cling paper to replace the traditional disposable cling paper. Environmental advantages:

ü Provides an all-natural, biodegradable solution for plastic boxes and plastic wrap wrappers. ü Alternatives to plastic, use natural materials as much as possible. ü Alternative biodegradable solutions to clingfilm to combat leaks and spills. ü Bento box style containers instantly halve the amount of packaging required, by removing lids. ü Reusable, create valuable products, and build a system to allow consumers to be rewarded for positive behavior. ü Commodity mechanism, slowly opening the existing takeaway culture, and at the same time promoting the concept of environmentally friendly takeaway. Good User Experience:

ü It can be creating packaging that can be used for display helps to create a sense of occasion at home.

Cons

✗ Higher initial cost than other eco-friendly options especially sharing economy is still an unfamiliar concept in HK. ✗ It may take up a lot of space for storge in the restaurant or transportation. ✗ The size of each layer is the same, which makes it more difficult to put the food in proportion, and some seasonings and sauces may not have suitable capacity for putting them.

MA T RI X ’ S C H A RT

Bagasse Take-out Container

Poly-coated Kraft Paper Containers

PLA Plastic Containers

Reusable Polypropylene Containers

PrepNaturals Glass Containers

Collapse-it Silicone Stainless Steel Food Food Storage Container Containers Sampler Pack

Le Creuset Stoneware Canister with Wood Lid

Cocoa Shell Recycled Lunch Box

Design Criteria

Weight

Aesthetic

Less Costs

Easy To Clean

Waterproof

Oil Resistant

Durability

Microwaveable

Freeze Safe

Light

Not Absorb

Plastic Free

Environmentally

Biodegradable

Reusable

3d Printing

Taste, Smell Or Stains Less Storage Space.

Friendly

Total

The results showed that PLA plastics scored the highest, which is less costs, waterproof, freeze safe, light, plastic free, biodegradable, recyclable and can be 3D printed.

POSITIONING MAP

ENVIRONMENTALLY PROTECTION

FEATURES

The positioning map shows the features and environmental protection of food containers as matrix as environmentally friendly materials and product features are the key elements to tackle with the food waste and disposable containers waste issues.

OPPORTUNITY GAP The fast-paced lifestyle has exacerbated the food waste problem in Hong Kong. Food delivery service has become the new normal in the anti-epidemic period. This has also led to a surge in the number of disposable food containers and tableware. Consequently, the purpose of the design is to make Hong Kong people more aware of wasted food, and to encourage and change people’s habit of using environmentally friendly food containers and tableware. In matrix's chart, PLA plastic scored the highest, being lower cost, waterproof, freeze-safe, lightweight, plasticfree,

biodegradable,

recyclable,

and

3D-printable.

However, aesthetics and durability scored low, so the design direction was to look at other biodegradable food waste or food by-product combinations to address the pain points of materials on the market today. The

positioning

environmentally

map friendly

should

also

materials

focus

and

product

characteristics and solve the key elements of food waste and disposable container waste.

PROPOSAL

PROJECT BRIEF

STATEMENT Hong Kong has low recycling rate for food waste. According to EPD, only about 1% of the total food waste produced in Hong Kong is recycled. With more and more people realizing the importance of maintaining earth’s

ecological

balance,

applications

biodegradable materials have become a sustainable development trend in different industries. Therefore, a brand-new design arises by transforming biodegradable food waste/ food by-products into stable, hard bioplastics, thus generating valuable product design ideas. The design direction is to study combinations of 100% biodegradable food waste or food by-products and convert them into base materials that can be produced. In

addition,

explore

opportunities

for

applications of bioplastics. It is also economical while bringing opportunities to design. To solve the problem of food waste while also providing a forward-looking alternative to the problem of disposable lunch boxes and tableware, hoping to encourage consumers to reduce the use of disposable lunch boxes and tableware, and contribute to the reduction of plastic waste globally.

OBJECTIVES To explore and test of various potential biodegradable materials, and to find out their possible applications. To

achieve

the

efficiency

and

sustainability

environmentally friendly production of materials and design. To create unique and innovative designs elements. To tackle the challenges that users may face in daily

life and to identify alternative design opportunities. To meet production requirements and standards for the materials used. To provide other environmentally friendly food waste disposal methods, and at the same time raise awareness of the sustainable development of food waste.

Environmentalist/ Eco-Minimalist Since environmentalists and Eco-Minimalist usually have a certain degree of concern and

sensitivity

environmental issues, they are more willing to buy and support relatively sustainable products.

Young people, Workers Who frequently eating takeaway Young people are more willing to accept innovative things. In addition, due to the low consumption power of young people, if there are more incentives and reasonable for them to use some recycled product, it will be cheaper than the usually takeaway payment. Therefore, it is affordable and reasonable for them. In addition, more

young

people

use

social

platforms, so they will share some special

things

through

these

platforms, which can also convey and promote the environmental design concept of to others.

TARGET USERS

DESIGN CRITERIA

Specification Performance

The design should be firmly protecting the food. The design should be easy to carry. The design should be portable. The design could combine the handle/ keeper and lunch box as one. The product could be including tableware and drink container. The design should be convenience to hold while eating. The product could be microwavable, freezer-safe and safe for dishwasher.

User Experience

Relieved and felt less quilty while using the product. Followed the clear instructions for the product treatments.

Material

The product should be hard and stable. The product should be waterproof, leak proof, water impermeable, hightemperature resistance. The design could be used of two-shot injection molding such as adding Pure PLA waterproof shell in the eating parts.

Environmental

The design should be used biodegradable and sustainable materials.

Advantages

The design should be fully sorted and decomposable after exhausted. The product should be reusable. The product should promote the environmental awareness of sustainable development.

Size & Weight

The product capacity should be enough for different kind of food. Food containers should be large enough for takeaway food.

Color & Style

The color of the design should be organic and could induces appetite. The product could be maintaining the organic feels of materials or dyed with natural color. Boxes stacking or separated squares perfect for separate equal quantities of food.

TIME SCHEDULE

MATERIAL TESTING

INTRODUCATION 91

Eggs and their shells come

The goal of the test is to be

from natural sources. This

able to find a new hard

means they have a high level

material that is decomposable,

biodegradable and reusable

addition, eggshells are the

created by food waste, thus

main

solving the current problem of

biodegradability. component

calcium.

Calcium

of helps

plants build strong cell walls and promotes their growth. For

eggshells,

they

are

biodegradable. Since they

are natural, there is nothing to stop them from breaking down,

they

are

biodegradable. The purpose of the test is to investigate the creation of bio-polymers using a wide range

bio-degradable

materials. Then to analyze

the

properties

the

different samples through material testing. In addition, to

Investigate

combination materials Acid

explore

with

PLA

the such

Polylactic

polymer whether

and such

materials may potentially be suitable process.

for

printing

food waste.

RECORDS 1

Method Tools: Molded, Mixed, Air Oven, Gas stove, Teaspoon, Dried, Parch Measuring Cup, Cooking pot, Scale, Grinder, Stirring spoon, Container or bowl, Mold, Sieve, Brush, Flat surface Test 1 (fail) Materials: Recipe - Water - Eggshell powders - Fish Scale powders Process Details: Step 1 Preparation of eggshells:

Collect as many eggshells as require from home, bakery, cafés, and other locations. Step 2 Wash the eggshells thoroughly, add the flour to remove odor and boil them for about 15 mins to kill all bacteria.

Step 3 To dry the eggshells:

1. Break the eggshells so that can parch a large number of eggshells at once. 2. Place the eggshells in the oven for 30 minutes at 180 degrees, but the eggshells need to be dried out; brittle but not burnt.

Source: - Self-Created

Portions: - 20 ml - 20 grams - 05 grams Photos:

Step 4 Put the eggshells in a blender and ground them down to the smallest pieces possible, then filter the powder. Attempt to obtain the finest powder possible.

Step 5 Preparation of fish scales:

Collect as many fish scales as need from home, water market, etc.

Step 6 Wash the fish scales thoroughly and add the flour to remove odor.

Step 7 To dry the fish scales:

Place the fish scales in the oven for 30 minutes at 180 degrees. Subtle crackling sound means that the fish scales are ready.

Step 8

Put the fish scales in a blender and ground them down to the smallest pieces possible, then filter the powders.

Step 9 Mix all the ingredients together:

First sieve the 5 grams of fish scales in a mixing bowl. Add 20ml of water to the bowl, mix thoroughly and cook until boil.

Step 10 Gradually add the 20 grams of eggshell powders into the water-fish scales mixture until a thick slurry is formed and all the ingredients are mixed well.

Step 11 Pour the mixture into a mold. Let the composite dry and do not touch.

Drying options as follows: -

OVEN: 150 degrees for 30 minutes AIR DRY: Can take 24 hrs+

Result It is failure. There is a layer of plastic-like touch film on the surface, which should be extracted from fish scales. Although it has solidified and formed, it is not hard enough to be used in products.

Test 2 (failure) Recipe

Process Step 1

Materials: - Water - Eggshell powders - Fish bones powders Details: Preparation of fish bones:

Collect as many fish bones as require from home.

Step 2

Wash the fish bones thoroughly, boil them for about 15 mins to kill all bacteria and let it separation of flash.

Step 3

Place the fish bones in the oven for 30 minutes at 150 degrees to dry the fish bones.

Step 4

Put the fish bones in a blender and ground them down to the smallest pieces possible, then filter the powder. Attempt to obtain the finest powder possible. * The amount of fish bones is relatively small, needs to change a small grinder to make it finer.

Portions: - 20 ml - 10 grams - 05 grams Photos:

Step 5 Mix all the ingredients together:

First sieve the 5 grams of fish bones in a mixing bowl. Add 20ml of water to the bowl, mix thoroughly and cook until boil.

Step 6 Gradually add the 10 grams of eggshells into the water-fish bones mixture until a thick slurry is formed and all the ingredients are mixed well.

Step 7 Pour the mixture into a mold. Let the composite dry by oven 180 degrees for 30 minutes

Result

100

It is failure. The composite was stuck to the mold and couldn't take it out. Only could buckle it out piece by piece, and it would dissolve in water.

Test 3 (half successful) Recipe

Materials:

Water Eggshell powders Shrimp shell powders Cassava starch water

Process Details: Step 1 Preparation of shrimp shell powders:

Portions:

10 ml 2.5 grams 2.5 grams 1.25 ml

Photos:

Collect as many shrimps’ shells as need from home.

Step 2 Wash the fish bones thoroughly, boil them for about 15 mins to kill all bacteria, and put the shrimp shells on the balcony to air dry.

Step 3 Put the shrimp shells in a blender and ground them down to the smallest pieces possible, then filter the powder.

101

Step 4 Mix all the ingredients together:

First sieve the 2.5 grams of shrimp shells and 2.5 grams of eggshell powders in a mixing bowl. Add 10ml of water to the bowl, mix thoroughly and cook until boil.

Step 5 Gradually add the 1.25 ml of cassava starch water into the water-shrimp shells mixture until a thick slurry is formed and all the ingredients are mixed well.

Step 6 Pour the mixture into a mold. Let the composite dry by oven 180 degrees for 30 minutes.

102

Result It is half successful. The surface is smooth, the shape is complete and beautiful, but it may not be too hard.

*Smells like shrimp crackers.

103

Metho d Molded , Mixed, Air Dried

Tools:

Source:

Cooker/stove/hotplat e, teaspoon, measuring cup, cooking pot, oven, grinder, stirring spoon, container or bowl, mold, sieve, fan, electric scales

Created By: Midushi Kochhar. Link: https://materiom.org/recipe/122 Author: Midushi Kochha Link: https://midushikochhar.squarespace.co m/ Web - Inspired by Eggshell Biocomposite from LABVA - Materiom Recipe 60

Test 4 (successful) Materials: Recipe - Water - Eggshell powders - Calcium alginate Process Details: Step 1 For the preparation of eggshells, collect many eggshells from daily waste or some restaurant/ bakery.

Step 2 Wash the eggshell thoroughly and boil it for about 15 minutes. The eggshell coat can be kept because the next step will be sieve out. This step can kill all the bacteria in the eggshell under high temperature. Step 3 Put the eggshells in the oven at 100 degrees for about 15 minutes. Adjust the time according to the number of eggshells. The important thing is that the eggshells need to be dry and brittle, but not burnt.

104

Portions: - 200 ml - 30 grams - 10 grams Photos:

Step 3 Put the eggshells in the oven at 100 degrees for about 15 minutes. Adjust the time according to the number of eggshells. The important thing is that the eggshells need to be dry and brittle, but not burnt. Step 4 Use a grinder to grind the eggshells into small particles, and then pass the powder through a sieve to get a finer powder for use.

Step 5 Add 10 grams of alginate and 200 milliliters of water to the mixing bowl (PP) and stir. There will be lumps at the beginning, and it takes about an hour to turn into a thick paste. Then, gradually add 30 grams of eggshell powders to the calcium alginate mixture and mix thoroughly. Step 6 Pour the mixture into a mold. Let the composite dry and do not touch. Depending on the thickness of the sample, the drying time can vary. Air dry for 24 hours.

105

Result It is successful. The composite is hard and not easy to break.

106

Method Tools: Molded, Mixed, Air Cooker/stove/hotplate, Dried, Parch teaspoon, measuring cup, cooking pot, oven, grinder, stirring spoon, container or bowl, mold, fan Test 5 (successful) Materials: Recipe - Water - Gelatine - Eggshell powders Process Details: Step 1 Preparation of eggshell powders.

Source: - Improving recipes on the internet

Portions: - 5 - 2 - 2 Photos:

Step 2 Mix according to the recipe and pour into the molds.

Step 3 Place the mold in the oven at 80 degrees for 65 minutes.

107

Step 4 The materials are still soft when you take them out from the molds, so leave them to dry for a week in a ventilated area.

Result After one week, the material becomes very hard.

108

Other Fail Testing

Recipe - 10 ml, Water 10 grams, Eggshell powders 2.5 grams, Pounce

Result It shatters as soon as it is demolded and cannot be condensed together.

Photos

- 10 ml, Water It shatters as soon as it is 10 grams, Eggshell demolded and cannot be powders condensed together. - 05 grams, Shell Powders

- 30 ml, Glycerol - 30 grams, Agar - 400 ml, Water 100 grams, Eggshell powders

The texture is too soft and not hard enough, and it will seep water, and the eggshell will fall off the surface after drying.

109

- 20g mixture (1 A rectangular box was water :0.04 xanthan) : used as a mold. The effect 50g eggshell powders was good at first, but it was not strong enough after it was completely dried, and it would crack when touched by hand, making it very fragile. 1tsp, Vinegar 1/2tsp, Glycerin - 2tsp, Starch - 8tsp, Water 2tsp, Eggshell powders -

110

5 grams, Calcium Alginate - 30 ml, Water 20 grams, Eggshell powders

It is difficult during boiling the mixture. The temperature and time must be controlled very accurately to prevent it to burnt. As a result, the is mixture will crack after drying. Put the composite into the mold, and then gently pour vinegar on the surface to make it react and solidify. However, this method causes the curl surface while the inside of the mixture is still moisture.

Properties Testing on Testing 4 Method Result Water Resistance 1 û Submerged the composite in water for a few seconds and the surface can be scratched off.

Photos

Water Resistance 2 û Use calcium alginate mixed with water and coated on the composite material as a coating, but it will be separated from the composite material.

Hardness ü The composite is crushed after being hit 10 times with a hammer with normal power.

111

Fall Test ü Drop the composite at 1 m and 2 m and it was perfect as before.

Decomposition ü The composite material was buried in the soil on the first day and watered every few days. After 14 days, the composite material softened and merged with the soil. The results show that it can be decomposed.

112

SUMMARY:

Eggshells proved suitable as a base material for bio-polymers without significant heat treatment.

Uniform eggshells powder is easier to work with

Mixture consistency meant more controllable results

Air drying was initially effective, but consistency was difficult to achieve

Not waterproof. If the composite material is to become a tableware or container, it must be waterproof.

Subsequent to broad material experimentation, the focus was narrowed to eggshells and PLA

PLA granules can be ground to a powder

Eggshells material was sterilized and ground to powder

High temperature resistant aluminum mold could create

Commercial oven with precise temperature control was used to blend eggshells with PLA polymer.

Results provided by FYP supervisor: Mr CHOY Yip Hong Sonny

113

RECORDS 2

114

COMBINE PLA AND EGGSHELLS The best result was obtained when combining PLA and eggshells. From different percentage ratio of eggshells and PLA, the optimal content of eggshells in PLA is about 10% to 20%. It is more stable, harder, smoother and more water resistant among all results. As PLA could be 3D printed, it has the potential to convert eggshells-PLA to 3D printable form and explore more applications based on the physical properties. Future

Goal:

The compositions of the whole

materials composites are eggshells.

Samples provided by FYP supervisor: Mr CHOY Yip Hong Sonny 115

DOUBLE SHOT INJECTION MOLDING

116

Photo Source: Gemini Group( 2021), https://geminigroup.net/plastics/two-shot-andinjection-molding-tpi/processes/two-shot-multi-shot/

What is double shot injection molding?

Double shot injection molding(2-

produce custom plastic parts such

Shot

as soft-grip handle inserts, multi-

injection

Molding)

efficient and cost-effective method

colored

for molding custom plastic parts

instrumentation,

with two or more plastic resins or

molded seals, flexible hinges, or

colors in one operation.

movable components.

parts,

dashboard or

parts

or with

In double shot injection molding custom plastic injection molding, plastic polymers from two or more injection units are applied through independent nozzles on one plastic injection

molding

machine

117

118

THIS TECHNOLOGY ENABLES:

Multi-color, multi-material and multi-component parts

New and wider range of designs

More complex parts and reduced cost

Production, handling and assembly efficiencies and savings

Reduction of multiple and secondary operations

Lower part cost

Enhanced product features and appeal, including tactile, ergonomic and aesthetics

Improved part and end use product integrity and quality

Elimination of secondary process for logos, graphics and text

à Design could be used of two-shot injection molding manufacturing feature by adding pure PLA waterproof shell in the eating parts to make it waterproof and safety.

119

120

IDEATION

MOOD BOARDS 121

122

THUMBNAILS 123

124

CONCEPT SKETCHES

125

Inspired by many restaurants in Hong Kong, especially cha chaan teng or some noodle restaurants, when purchasing some noodles with soup, they will provide customers with the separation of soup and noodles. The noodles are placed in the upper container, and the lower layer is the soup. The benefit of this measure is to

INPIRATION

keep the noodles fresh and prevent the noodles from absorbing the soup.

Apart from catering to the eating habits of Hong Kong people, the food containers set also includes assemblable tableware, which are stored in the container. In addition, baffles are also included as to separate different foods to keep the food fresh and tasty.

CONCEPT

Cooperate with GREEN@COMMUNITY The Environmental Protection Agency has been developing a new community recycling network, GREEN@COMMUNITY. They actively contacted housing estates and property management companies in the community, established a service network, set up recycling mobile points in the community. In addition, they are also implementing recycling of PLA items. Therefore, it's possible to establish a partnership with them. To add a new item as food containers in the existed recycling regions. Collect and process these items with their assistance.

126

Many times, there are many large and small containers at home, which take up a lot of cabinet space and are inconvenient to carry. So why not implement multiple

containers on top of each other? Also, the size between the containers is just right.

INPIRATION

The smaller container fits just right into the larger container and can be completely stowed away when not in use. When in use, smaller containers

can be stacked on top of larger containers, and the lid can also be rotated according to the user's usage.

CONCEPT

127

The design inspiration of the two is relatively close, and both want to use the slide rail to achieve the purpose of storing tableware. In addition, compared with the previous concept, the shape is closer to a rectangle, and the capacity is relatively small.

INPIRATION

The concept in the upper left corner is that the cutlery box can be inserted into the container lid, flush with the lid, keeping the box shape and tidy. The concept in the bottom right corner is that the lid and handle section can slide in and out of the container. On the back of the lid part, cutlery can be stored into the cavity.

CONCEPT

128

FORM EXPLORATION

129

130

131

DEVELOPMENT SKETCHES

132

133

134

135

136

137

138

139

140

141

142

SUMMARY

143

In summary, the design concept and expected results of the above suggestions are put forward in terms of food waste treatment. Through the design of eggshells food container project, it is not only possible to prevent and reduce the waste of eggshells, but also to recycle eggshells into valuable products. Eggshells food containers can be disposed of with food waste and then converted into biogas with the help of anaerobic digestion as a source of green energy and nutrient-rich biofertilizers. It has a lot of potential. It takes time to establish a complete food waste recycling system in Hong Kong. In the process, it continues to improve. The ultimate goal is to improve our environmental footprint through sustainable recycling and production of highvalue products.

144

FOAM MODELLING 145

H E R O

F o o d 146

S H O T

C o n t a i n e r

S e t

Container Cover with Handle

147

Storage Status: After Twist Down the Cover

148

With Food Status: After Twist Up the Cover

149

Before Assembled

150

After Assembled

151

MODEL TESTING

152

Usual size of containers can’t fit into the cabinet.

~ 25cm for the container height after stored into one. Totally fit into the kitchen cabinet. SIZE TESTING

153

HOLDING TESTING

Suitable size and handle curve for holding.

154

V OL U ME TESTING

The volume of smaller container can put around 1kg raw rice. Around 1.2kg raw rice for the large one.

155

Adult man eat an average of 200 grams of rice per meal, which can be increased to 400 grams according to activity. Adult women eat an average of 160 grams of rice per meal, or 320 grams if they are active. After

the

rice

cooked,

the

volume will expand by about 2.5 times to 3 times. Therefore, the larger

container

with

1.2kg

volume can hold up to 400g of cooked

rice,

which

can

satisfy

the largest amount of rice for adult men.

156

IMPROVEMENT

When the container was in twist in status, it was found from the test model that the storage space for cutlery was insufficient. To fix this, it has to adjust the height of the small container.

Our common tableware usually includes chopsticks, so chopsticks can add this series. In terms of design, it needs to meet the characteristics of space saving, and the size should not exceed the cover of the small container.

Although this model does not make baffle and the containers for separate the soup and noodles, this two items should be placed inside small containers considering the space after twisting in.

157

BRAND PLAN

158

SAVE SPACE. SAVE WASTE.

Brand Name Inspiration EGGSAVE consists of two parts, EGG represents that the product will be mainly composed of eggshells as a natural material. SAVE means save and avoid, which means to avoid unnecessary waste and turn it into a valuable product. Also, it features space saving.

Brand Story Compared with many well-known brands on the market, EGGSAVE is made by an immature and unknown university graduate. However, she still hopes to gain public attention through different forms. Compared to traditional food containers on the market, EGGSAVE wants users to discover interesting product innovations and gain more awareness of sustainable materials when purchasing.

Vision and Mission Vision Statement: "Make the world a cleaner and more beautiful place. Use creativity to gradually solve the current environmental crisis.” Committed

cooperating

with

environmental

protection

organizations, we use kitchen waste as raw materials to produce, process and recycle through different channels. The goal is to make kitchen waste recycling products the most popular products.

159

160

DIMENSION DIAGRAMS

161

162

163

164

Ite ms

Part Name

Qty

Materials

Manufacturing Process

Cover with handle