Design of Self-heating Instant Noodle Packaging by Ei Thae Ponnami Mya Tin A thesis submitted in partial fulfillment of the requirements for the degree of Master of Engineering in Industrial and Manufacturing Engineering Examination Committee: Assoc. Prof. Erik L.J. Bohez (Co-chairperson) Dr. Huynh Trung Luong (Co-chairperson) Prof. Barbara Igel Dr. Mongkol Ekpanyapong Nationality: Myanmar Previous Degree: Bachelor of Engineering in Mechatronics Yangon Technological University Yangon, Myanmar Scholarship Donor: AIT Fellowship Asian Institute of Technology School of Engineering and Technology Thailand May 2017 i ACKNOWLEDGEMENTS I wish to show my deep sense of gratitude to my Assoc. Prof. Erik L.J. Bohez for his valuable knowledge, guidance, worthy recommendation and great comments throughout the whole period of my association with AIT. Without him, my thesis would not have been completed. Sincere thanks are conveyed to Dr. Mongkol Ekpanyapong, for his interest in my work and his comments during my thesis period. And also I would like to thank to Prof. Barbara Igel and Dr. Huynh Trung Luong; for their valuable suggestions and recommendations. This thesis would not have been possible without the support of my family members and my beloved husband. Because of their love, understanding and support, I can accomplish my work on time. Thanks all of my friends and classmates who helped in collecting data about my packaging design and customer needs. I would like to show my sincere appreciation to my bestie who always ready to help me during my thesis period. A special thanks goes to Ms. Mya Hpoo Ngone, Ph.D candidate, who let me to use her Environmental Engineering Management Lab at any time and also her lab equipment to measure the temperature of chemical reactions in lab test. At last but not least, all of my gratitude goes to all of my Industrial Systems Engineering faculty members, staffs and seniors for their great inspirations. ii ABSTRACT A kind of instant noodle who applying advanced technology; self-heating technology to make the people daily life getting easier and better. Design of the self-heating instant noodle package is based on the results of the questionnaires according to the survey of different nationalities. Three new design concepts were investigated and two types of heat producing methods were considered to apply in packaging design based on the Quality Function Deployment Method (QFD). After studying the current designs of instant noodle, the design of self-heating noodle has been determined. The packaging materials were chose according to their physical and chemical properties especially their temperature resistance in long term period. To get the right portion of chemical mixture, several lab tests have been done. The most important aspect of new design was focus on a kind of instant noodle packaging which does not need fire or electricity to get a hot and delicious noodle soup. Once the chemical reaction has been activated, the heat will be produced and a cup of hot noodle soup will be delivered within minutes. Keywords: Instant Noodle, Self-heating, Quality Function Deployment (QFD), Packaging Design iii TABLE OF CONTENTS (Cont’l) CHAPTER TITLE PAGE TITLE PAGE i ACKNOWLEDGEMENT S ii ABSTRACT iii TABLE OF CONTENTS iv LIST OF FIGURES viii LIST OF TABLES xi 1 INTRODUCTION 1 1.1 Background of study 1 1.2 Statement of the problem 2 1.3 Objectives of the study 2 1.4 Scope and limitation 2 2 LITERATURE REVIEW 3 2.1 Introduction of packaging 3 2.1.1 Definitions of packaging 3 2.1.2 Packaging and its functions 3 2.2 Origin of noodle 4 2.3 What is instant noodle? 4 2.3.1 Instant noodle production 4 2.3.2 History of instant noodle 5 2.4 Marketing research 5 2.4.1 Instant noodle demand all over the world 5 2.4.2 Instant noodle demand in Thailand 7 2.5 Instant noodle packaging materials 9 2.6 Packaging layout of cup noodle 11 2.7 Active packages 11 2.8 Criteria for self-heating system 12 2.8.1 Principles of self-heating packages 13 2.9 Self-heating package for instant noodle 13 2.10 Quality function deployment process 14 iv TABLE OF CONTENTS (Cont’l) CHAPTER TITLE PAGE 2.10.1 A brief review of QFD history 14 2.10.2 Functions of QFD 14 2.10.3 Building a house of quality 16 3 METHODOLOGY 17 3.1 Flow chart of methodology 17 3.2 Determine heat generating method 17 3.3 Study on heat condition 18 3.4 Study of self-heating technology packages 18 3.4.1 Self-heating package with aluminum can 18 3.4.2 Self-heating can of heat genie technology 19 company 3.4.3 Self-heating package of pouch-in-pouch 19 design by Scaldopack Company 4 QULAITY FUNCTION DEPLOYMENT(QFD) AND 21 DESIGN CONCEPT 4.1 Mission statement 21 4.2 Survey of customer requirements about instant 22 noodle and the packages 4.3 Result analysis 22 4.4 Importance of customer needs 22 4.5 Product specifications 23 4.6 Quality function deployment 24 4.6.1 Steps for Quality function deployment 24 4.7 Customers needs matric-matrix 26 4.8 Correlation matrix 28 4.9 Competitive assessment and score of customer 29 needs 4.10 Ranking of customer needs specifications 30 v TABLE OF CONTENTS (Cont’l) CHAPTER TITLE PAGE 4.11 Concept generation 32 4.12 Sample design of self-heating noodles packages 32 4.13 Concept generation 34 5 HEAT GENERATING METHOD AND 39 LABORATORY TEST 5.1 Determine heat generating method 39 5.2 Select appropriate method of exothermic reaction 39 5.3 Determine heat generating method 40 5.3.1 Study on heat condition 40 5.4 Lab equipment 42 5.5 Laboratory experiment 42 5.5.1 Lab test 1 (18 gram of Mg mixture) 43 5.5.2 Lab test 2 (27 gram of Mg mixture) 46 5.5.3 Lab test 3 (36 gram of Mg mixture) 49 5.5.4 Lab test 4 (45 gram of Mg mixture) 52 5.5.5 Lab test 5 (40 gram of Mg mixture) 55 6 NEW DESIGN ALTERNATIVES 59 6.1 Selected package deign 59 6.2 Design specifications 60 6.2.1 Outer noodle cup 60 6.2.2 Inner noodle cup 61 6.2.3 Cap design 62 6.2.4 Final design 62 6.3 Packaging label design 63 6.3.1 Labeling and printing 63 6.4 Material selection 67 6.5 Types of different packaging material 68 6.6 Materials selection for self-heating instant noodle 68 package vi TABLE OF CONTENTS CHAPTER TITLE PAGE 6.7 Characteristics of selected materials 69 6.7.1 Laminated materials 69 6.7.2 Polypropylene materials 69 6.7.3 Non- woven Fabric (Polyester fiber) 71 7 MASS PRODCUTION, PACKAGING LAYOUT 74 AND FEASIBILITY PLANNING 7.1 Packaging layout 74 7.2 Machine selection 74 7.2.1 De-palletizing machine 74 7.2.2 Automatic activated carbon packaging 75 machine 7.2.3 Ink jet printing machine 76 7.2.4 Filling machine 77 7.2.5 Shrink wrapping machine 78 7.3 Feasibility planning 80 7.3.1 Direct cost 80 7.3.2 Indirect cost 81 7.4 Production capacity 83 7.5 Estimated selling price 84 8 CONCLUSION AND RECOMMENDATIONS 85 8.1 Conclusion 85 8.2 Recommendations 85 REFERENCES 87 APPENDIX 88 vii LIST OF FIGURES (Cont’l) FIGURE TITLE PAGE Figure 1.1 Current cup package design of instant noodle that need to 2 add hot water Figure 2.1 The World First Instant Noodle “Chikin Ramen” and the 5 inventor “Momofukuando” Figure 2.2 Instant Noodle demands all over the world 7 Figure 2.3 Instant noodle demand in Thailand 9 Figure 2.4 PET noodle cup coated with paper (MAMA Brand) 10 Figure 2.5 Polypropylene noodle cup (NISSIN Brand) 10 Figure 2.6 Thick and good quality Polystyrene noodle cup (KOKA 10 Brand) Figure 2.7 Self-heating packages that can available in the market 12 Figure 2.8 Self-cooling package branded i.c.can 12 Figure 2.9 Criteria for self-heating system 13 Figure 2.10 House of Quality: driving force for QFD process 16 Figure 3.1 Methodology flow chart 17 Figure 3.2 Self-heating Nescafe can in market 18 Figure 3.3 Self-heating can design of heat genie technology company 19 Figure 3.4 Pouch-in-pouch self-heating package (press type) 19 Figure 3.5 Pouch-in-pouch self-heating package (hand-shaking type) 20 Figure 4.1 Mission statement 21 Figure 4.2 Concept development process of new design innovation 23 Figure 4.3 House of quality 25 Figure 4.4 Correlation matrix 28 Figure 4.5 Sample design of self-heating noodle packaging 34 Figure 5.1 Heat transfer within package 40 Figure 5.2 Tempearture variation curve of 18gram of Mg mixture 44 Figure 5.3 Time behaviour graph for the observation that produced 45 maximum temperature (18gram) Figure 5.4 Time behavior graph for the observation that has longest 46 period at stable temperature (18gram) viii LIST OF FIGURES (Cont’l) FIGURE TITLE PAGE Figure 5.5 Tempearture variation curve of 27gram of Mg mixture 47 Figure 5.6 Time behaviour graph for the observation that produced 48 maximum tamperature (27gram) Figure 5.7 Time behavior graph for the observation that has longest 48 period at stable temperature(27gram) Figure 5.8 Tempearture variation curve of 36 gram of Mg mixture 50 Figure 5.9 Time behaviour graph for the observation that produced 51 maximum tamperature (36gram) Figure 5.10 Time behavior graph for the observation that has longest 51 period at stable temperature(36gram) Figure 5.11 Tempearture variation curve of 45gram of Mg mixture 53 Figure 5.12 Time behaviour graph for the observation that produced 54 maximum tamperature (45gram) Figure 5.13 Time behavior graph for the observation that has longest 55 period at stable temperature(45gram) Figure 5.14 Tempearture variation curve of 40gram of Mg mixture 57 Figure 5.15 Time behavior graph for the observation that has longest 58 period at stable temperature(40gram) Figure 6.1 Outer cup design 61 Figure 6.2 Inner cup design 61 Figure 6.3 Cap design 62 Figure 6.4 Final design 62 Figure 6.5 Label