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thesis entitled

Cushioning Performance of Molded Pulp (E-Cubes) Loosefill

presented by

Geeta Govindan

has been accepted towards fulfillment
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I
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CUSHIONING PERFORMANCE OF LOOSE FILL (E- CUBES) MOLDED PULP

BY

GEETA GOVINDAN

AN ABSTRACT OF A THESIS

Submitted to
Michigan State University '
In partial fulfillment of the requirements for the degree of
MASTER OF SCIENCE
School of Packaging
2001

Dr. Paul Singh

. ABSTRACT

CUSHIONING PERFORMANCE OF MOLDED PULP (E-CUBES) LOOSEFILL
BY

Geeta Govindan

This thesis involves a study of a new type of loosefill : E-cubes, made of recycled
paper pulp. The two types of Eecubes tested were: Low and High Density.
ASTM test procedures were used to check the shock absorbing properties. The
data . obtained was plotted as. Gmax versus static loading. This enabled the
comparison of data for both types of E-cubes for two different thicknesses and

two different drop heights.

ASTM D-4728 was used to. check the effect of random vibration on settling of
products when loose fill E-cubes are used. Three different sizes of spherical
shaped objects were used to determine'the settling rate. The settling rate of the

spherical objects was compared to that of EPS loosefill.

The results showed that this material is higher in cost than EPS loosefill, and
shows a higher shock transmission as comparesd to EPS loosefill. However it
has extremely good interlocking capability and prevents products from settling

due to vibration.

Cepyri ght by
' Geeta Govindan
200 1

 

- . ‘ ACKNOWLEDGEMENTS

* i wish to express my deepest and sincere appreciation to my major
professor, Dr‘.S. Paul Singh for'his assistance, guidance and encouragement
throughout my research. l would like to extend my thanks and gratitude to the
other members of my graduate committee, Dr; Gary Burgess and Dr. Brian
Feeny for their valuable inputs.

I would like to thank Tom Warda,‘ President of E-Teeh, for providing me
, the sample loose fill material for my research. ,I would also like to thank J. Singh
for all. the help he provided.

i appreciate the support from faculty and staff of the School of Packaging

who helped me during the course of my graduate studies.

iv

TABLE OF CONTENTS

LIST OF FIGURES .............................................................................................. vi
LIST OF TABLES ................................................................................................. ix
CHAPTER 1: INTRODUCTION

1.1 Why use cushioning? .................................................................................... 1
1.2 Types of cushioning materials ...................................................................... 3
1.3 Comparison between Solid and loose till cushioning materials ................... 15
1.4 E-Cubes ...................................................................................................... 16
1.5 How are E-cubes different from other loose fills? ....................................... 18
1.6 E-Cubes dispensing system ....................................................................... 18
1.7 Current applications of E-eubes .................................................................. 19
1.8 'E-cubes current specifications .................................................................... 20
1,9. Objectives ................................................................................................... 22
CHAPTER 2: MATERIALS, METHOD AND TESTING OF E—CUBES

2.1 * Shock Test for E-cubes ............................................................................... 24
2.2 Vibration Study for E-cubes ..................................................................... 30
CHAPTER 3:. DATA, ANALYSIS AND RESULTS

3.1 Transmitted Shock Data ............................................................................. 37
3.2 Discussion of Random Vibration test .......................................................... 47
CHAPTER 4:“ CONCLUSIONS .......................... . ................................................. .52
APPENDICES

APPENDIX A: SHOCK DATA ............................................................................ .53
APPENDIX B: VIBRATION STUDIES ........ . ......................................................... 61
APPENDIX C: PACKAGING COST COMPARISON ........................................... 79
APPENDIX D: ..................................................... . ................................................ 80
LIST OF REFERENCES ..................................................................................... 81

LIST OF FIGURES

' Figure - PAGE
1 , Bubble Wrap ............. . .................................................................................... 4
2 . Polyethylene foamcushion Block ........................................... . ..................... 5
3 Air-bag .......................................................................................................... 8
4 Single faced corrugated board ...... . ........................................ . ........................ 9
5a core of Honey-comb board ......................................................................... 10
. 5b rHoney-comb board ..................................................................................... 1O
6- . Expanded Polystyrene Lobse-fill ............................... . .................................. 11
7 . 'Wood Curls .............. ; .................................................................................. 11
8 Biodegradable lobse fill .............................................................. . ................. 14
9 The BAS dispensing at e—toys ..................................................................... 15
10a Grey High Density E-Cubes ........................................................................ 16
10b Green Low Density E-Cubes ... ................................................................... 16
11 Bulk dispensing system .............................................................................. 19
12a Test Block ..................................... , ........ . ..................................................... 26
12b Schematic drawing of the test block used for'shock test .............................. 27
13 Schematic drawing of the boxused forshock test ...................................... 28
14 Picture of a Shock table .............................................................................. 30
15 Vibration test ............................................................................................... 31
16 Settling test using Random Vibration33

 

, Figure ' - ' PAGE

17

18

19

20

21

22

23

24

25

26

27

28

Croquet ball before the vibration study ................................................. .34
Croquet ball after the vibration study .......................................................... 34
Wax ball, used in the vibration study ........................................................... 35
Pool ballused. in the vibration study ........................................................... 35
Two inches, High-density cushion, drop. height of 24 inches,

‘6’ Max of first drop ............................................................................... . ...... 39

' Two inches, High-density cushion,;drop height of 24 inches,

Average ‘6’ Max ......................................................................................... 39
Three inches, High-density cushion, drop height of 24 inches,

‘G’ Max of first drop ..................................................................................... 40

‘ Three inches, High-density cushion, drop height of 24 inches,

Average .‘G’. Max ........................................................................................ 40
Two: inches, High-density cushion, drop height of 36 inches,

‘G’ Max of first drop ..................................................................................... 41
Two inches, High-density. cushion, drop height of 36 inches,

Average ‘G’ Max ......................................................................................... 41
Three inches, High-density cushion, drop height of 36 inches,

‘6’ Max of first drop ..................................................................................... 42

Three inches, High-density cushion, drop height of 36 inches,

Average ‘G’ Max ......................................................................................... 42

vii

PAGE

' Figure
29 Two inches, Original-density cushion, drop height of 24 inches.
‘G’ Max of first drop .............................. , ....................................................... 43
30 Two inches, Original-density cushion, drop height of 24 inches,
Average ‘G’ Max ......................................................................................... 43
31 Three inches, Original-density cushion, drop height of 24 inches,
‘G’ Max of firstdrop ..................................................................................... 44
32 - Three inches, Original-density cushion, drop height of 24 inches,
Average ‘G' Max ......................................................................................... 44
33 Two inches, Original-density cushion, drop height of 36 inches,
‘G’ Max’ of first drop .................................................................................. -...45
34 Two inches, Original-density cushion, drop height of 36 inches,
Average ‘6’ Max ......................................................................................... 45
35 ' Three inches, Original-density cushion, drop height of 36 inches,
‘6’ Max of first drop ..................................................................................... 46
36 Three‘inches, Original-density cushibn, drop height of 36 inches,
Average ‘6’ Max ...................................................................................... '...46
37 Distance traveled by Pool ball in original and high strength loose fill .......... 49
38 Distance traveled by Wax ball in original and high strength loose fill .......... 49
39 Distance traveled by Croquet ball in original and high strength loose fill 50
40 Distance traveled by all three objects in original strength loose fill ............. 50
41 Distance traveled by all three objects in high strength loose fill .................. 51

viii

'LIST OF TABLES

TABLE PAGE

A1 . Cushion Material: High Strength, Drop height: 24", Cushion Thickness: 2” ........... 53

A2 Cushion Material: High Strength, Drop height: 24", Cushion Thickness: 3" ........... 54

A3 Cushion Material: High Strength, Drop height: 36”, Cushion Thickness: 2” ........... 55

A4 Cushion Material: High Strength, Drop height: 36", Cushion Thickness: 3” ........... 56
A5 Cushion Material: Original Strength, Drop height: 24", Cushion Thickness: 2” ...... 57
A6 Cushion Material: Original Strength, Drop height: 24", Cushion Thickness: 3" ...... 58
A7 Cushion Material: Original. Strength, Drop height: 36”, Cushion Thickness: 2' ...... 59
A8 Cushion Materialz’Original Strength. Drop height: 36", Cushion Thickness: 3” ...... 60
B1 Time Controlled Vibration Data, High-density Loose Fill, Blue Wax Ball ............... 61
B2 Time Controlled Vibration Data. High-density Loose Fill, Pool Ball ....................... 63
83 Time Controlled Vibration Data, High-density Loose Fill, Yellow Croquet Ball ...... 65
B4 Time Controlled Vibration Data, Original-densiteroose Fill, Blue Wax Ball .......... 67
B5 Time Controlled Vibration Data, Original-density Loose Fill, Pool Ball .................. 69
BS Time. Controlled Vibration Data, Original-density Loose Fill,

B7
BB
89

Yellow Crocket Ball .............................................................................................. 2.1
Distance Controlled‘Vibration Data, Original-density E-cubes, Pool Ball .............. 73
Distance Controlled Vibration Data, High—density E-cubes, Pool Ball .................... 74

Distance Controlled Vibration Data, Original—density E-cubes,

Yellow Croquet Ball .............................................................................................. 7.5

B10 Distance Controlled Vibration Data, High-density E-cubes,

Yellow Croquet Ball ............................................................................................. 26

311 Distance Controlled vibration Data, Original—density E-cubes, Blue Wax Ball ...... 77

B12 Distance Controlled Whration Data, High-density E-cubes, Blue Wax Ball ........... 78

ix

. CHAPTER 1: INTRODUCTION

1.1,Why Use Cushioning?

- During transportation, a product is subjected to various types of handling and
shipping hazards. One type of handling hazard is the accidentally dropping of
packages while loading them in vehicles. Due to the weight of the product, and
the velocity with which it falls, damage can occur. Transportation hazards could
result from the vibration of the truck while' traveling. When one packs a product
and ships it, it’s the individual’s responsibility to see that the product reaches the
customer safely. During transit, the product is likely to be damaged due to the
rigors of transportation. The term used to describe protection given to the
product from shock is cushioning. In orderto protect products during shipping,
one needs to use cushioning materials. The cushioning and protective packaging

should be done reliably and at a low cost. (Paine, 1967)

While selecting cushioning materials one needs to account for several properties
‘ including the following:
1. It shouldsignificantly reduce the damage rates to the product by providing

adequate shock absorption during drops. This will keep the G level felt by

the product as small as possible.

2. It should try to produce plastic impacts when the product is dropped. The

product should not bounce.

‘ 3. It should be durable enough to withstand a number-of drops and severe

weather conditions.

' 4. It is a requirement that the cushioning be light in weight. This will keep the

weight of package low.
5. It should fill voids and keep the product centered in cartons.
6. It should be manufactured with consistent properties.

7. It should be low in cost.

8. Cushioning materials are environmentally preferred if they are reusable or

biodegradable.
9. It should not‘be sharp or cause abrasion tothe product surface.

10. It is important that the cushioning material has good ‘compression set’
and ‘creep resistance. Compression set is the inability of- the material to
return to its initial thickness after shock. A cushion with poor compression
set property once compressed remains in that condition leaving .a void in
package that adds to damage apart from the fact that it has lost its

cushioning effectiveness. (United Parcel Service, 1975)

11.The weight of the product on the cushioning material compresses it over a
period of time; this is known as- ‘creep’. This happens to all types of
cushioning materials with a varying degree. Materials with high creep

resistance are preferred. (United Parcel Service, 1975)

1.2 Types of cushioning materials:

Various types of cushioning materials areavailable that can offer product

protection during shipping and handling.

,1.

2.-

Air encapsulated plastic (Bubble wrap)

Foam

Molded custom made inserts

Foam in place

Airbags

. Corrugated board

Loose fill:
a) Expanded Polystyrene peanuts (EPS)
b) Wood Curls
c) Shredded .corrugate board
d) " Shredded Paper
e) Biodegradable loose fill

f) E-cubes

1) BUBBLEWRAP:

 

Figure1: Bubble Wrap

Bubble wrap (Figure 1) cushioning is used for protecting all types of fragile
, products. Bubble wrap is. a lightweight material. It is made from flexible
polyethylene sheeting encapsulating air pockets, or “bubbles." This cushioning
offers versatility of. application. It accommodates a variety of sizes and shapes of
products requiring cushioning, surface protection, and void fill. Bubble wrap
meets packaging requirements for surface protection and small-item cushioning.
This cushioning product is commonly used in packaging machine parts,
glassware and small electronic elements.

Coatings —bubble wrap cushioning could also have adhesive and cohesive

coatings. They can be self-sealing. Using non-staining adhesive enables direct

application to products that eliminates surface damage. Cohesive bubble

adheres only -to itself and offers a wide variety 'of applications involving insulating

products from damage, void filling and keeping productsin place during shipping.

:2) FOAM

 

Figure 2: Polyethylene Foam Cushion Block

Foam structures can be of two types: “Closed-cell” foam or “ open cell” foam.
Closed cell foam consists of individual bubbles of air trapped within a thin
. unbroken membrane of plastic. The cells are fused together to form the cushion.
They absorb energy in an impact by compressing air. Expanded polystyrene is
used largely to make end caps for’products. They are stiffer durable and better
able to cushion heavy products. They are more expensive than the open cell
foam. EPS is however not a material of choice while considering packaging of

lightweight fragile products that require lower static loading. (Rogers, 1986)

Open cell foam consists of'a network of open cells. Air is able to flow between

cells. Example: Low-density polyethylene foam (Figure 2).

. There is a visible. difference between the open and! closed cell foam (United

Parcel Service, 1975). In addition open cell foam will absorb water and act as a

' sponge.

Recycled Green: Environmentally = friendly green polyethylene foam is
manufactured-from recycled resins. Fifty percent of the total weight consists of
secondary waste of which ten percent of the total weight consisting of post-

consumerwaste. (Papermartcom, 2000).

Foam: products such as EPS. (Expanded Polystyrene), EPE (Expanded
Polyethylene) and PU. (Expanded Polyurethane) arecustom made into molded

. cushions for inserts.
3) Molded: CUSTOMvMADE FOAM INSERTS: -

Depending on the design of a customer’s foam, solid cushions can be molded
and cut to suit product shapes. They can be made out of EPS (Expanded

Polystyrene), EPE and PU.

There are other types of inserts-that are made of molded recycled paper. These
. cushions are low in cost'and are mainly for lightweight product such as printer

and computer accessories. (Packaging World; 2000)
Advantages of using molded insert are:
1. They do not shift-inside the pack.

2. They also absorb a lot more impact energy.

Disadvantagesof using molded insert are:
1. They are expensive and are custom made to order.
2.. They are not biodegradable or easily recyclable.

Starch-based foam pieces can be molded; usingwater misting. Water soluble
starch pellets are lightly misted before packing, causing them to adhere to each

other and, then molded in place for protective ‘cushioning.

' 4) Foam .inplace: It is a chemical, Epoxy Poly Urethane, which is sprayed into
the box to form protective cushions. The foam in liquid state rises around the
contents and cures to become solid foam ‘cushions. It is used to provide
» cushioning to irregularly shaped heavy products like machinery parts. Plastic is
poured inside the outer pack in the form ofa foam. A plastic sheet is kept on top
of it and the product is placed with alplastic sheet on top and more foam is
sprayed around the. product. The box is then closed and the foam is allowed to
cure. The foam then expands and forms a kind of protective case around the
product. This is as versatile as loose-fill cushioning because it takes the shape of
the product. It is similar to molded custom made cushioning, and often cannot be
reused.

5) Air — Bags: An air bag is a plastic bag filled with air as shown in Figure 3. It is
made of Low Density Polyethylene so that it can be heat sealed after filling‘with
air. It could be as small as a bubble wrap, or it could be made as bigas a
mattress. The large air bags can. provide cushioning to pallet loads for lateral

shifting in trailers and rail cars.

Advantages:
- . It is a low cost cushioning material that is not messy-in application.
0 Could be used in all weather conditions.
Disadvantages:
.- If the product has a sharp edge it may puncture theairbag and deflate it.
. Asa result of air pressure inside the bag it may develop thin walls due to
the constant stretching of plastic which in due course of time may damage

. the bag.

 

Figure 3:Airbag

6)Corrugated Board:
Corrugated board is made of recycled kraft paper.

6.a) Single Faced Corrugate Board:.This is placed around the product so that it
absorbs the shocks during transportation. Single faced corrugate board is
wrapped around the product to give. it cushioning. It is one of the. cheapest

cushioning materials and can also be recycled: The properties of paper are

strongly affected by moisture and age. This type of cushion is sensitive to
'humidity. These cushions may be able to give adequate protection for single drop
situations but are not very effective for multiple drops. (Singh et-al,1994,).

Figure 4 shows the single face corrugated cushioning material.

 

Figure 4: Single faced corrugated board.

6.b) Honey Comb Board: It was first developed by the Structural Research
Laboratories at the University of Texas, Austin, specifically to pack single aerial
drop of military products. As seen in- Figures 5a and 5b honeycomb is made of a
network of cells that form the core. The core is gluedbetween two facings. It can
be made of different core sizes. The core usually has a 33 pounds basis weight
and the two liners have 69 pound basic weight each. Honeycomb offers
extremely high compression strength as compared to built-up corrugated board

cushions.

 

 

 

 

 

 

‘ V

F igure5a: Core 1 Figure5b: Honey Comb Board

 

 

 

 

 

 

 

 

 

 

 

7) Loose fill:

A wide variety of materials are used as loose fill cushioning. They are primarily
used to provide void filling of spaces in rectangular shaped cartons when
packaging odd shaped products. Some ofthe commonly used loose fill

cushioning materials are discussed in this section.

Expanded Polystyrene-Ioosefill:— The plastic pellets are extruded and then
eXpanded with heat. In order toobtain a low density the'pellets have to be
expanded after heating. Approximate density of EPS loosefill is 0.25— 0.30 lb/ft3.
One hundred percent recycled EPS is also available. It is green in color to signify
that it is recycled. In general Expanded Polystyrene whether it is recycled or
virgin is electrostatic sensitive. At low humidity it will cling to the product it is
packed in. This makes the packing and unpacking a messyprocess. (Singh,
Chonhenchob and Burgess 1994). However due to its extremely low cost EPS is

the most widely used type of loosefill in the United States today.

10

 

Figure 6z-Expanded Polystyrene Loose-fill
Wood shavings:

This material is. made from wood waste obtained from the lumber industry.

 

Figure 7: Wood Curls. (Papen'nartcom, 2000)

The. shavings: are of‘various shapes, sizes, and diameter as there is no
consistency in the method of manufacturing. Thedrawback in using this type of

loose fill is that it canbe abrasive to the-product. (Singh et-al,1994)

Shredded Corrugated Board /Corrufill:

- Before 1992, NDL Products Inc. used to throw away the incoming corrugated
boxes and used to pack their sports and fitness products in polystyrene peanuts.
They did not want to waste the corrugated boxes so they stopped 'buying
polystyrene peanuts. They bought a cardboard shredder and started using the
shredded corrugated boxes as loose fill. But the pieces Were too large and had a
ragged look. They were full ofsmall particles and paper dust. Due to customer
complaints they boughta corru-shredder specifically to chop the corrugated
board into uniform strips. The machine is 3 ft wide, 8 ft long, weighs about 400
pounds, and is mounted on wheels. It operates on 110 volts AC. The operator
prepares the feedstock by flattening the. cartons. Then whole boxes are slit into
strips, generally 4 to 6 inches wide, using a table saw. The width of the first cut
determines the length of a finished pieCe of packaging material. Next, the wide
strips of the box are fed into the Icorru-shredder for slicing into uniform, 1/8 — inch
—wide strips, The finished material, called ‘corru-fill', passes through a strong air
current to remove dust, and the material falls into a bulk container. As the
container fills, the contents are sprayed with biodegradable insecticide in an
alcohol based carrier. Machine maintenance includes daily oiling and occasional

sharpening of the four shear blades. On an eight hour shift with manual

12

‘ operators, the machine can produce about 1,500 lb, orapproximately 1000 cubic

feet of corrufill.

' . For equal volumes, chopped Corrugated box is significantly heavier than foam

polystyrene. However, when corru-fill is dumped loosely around products in
cartons, the exposed corrugations on the thin strips causes adjacent pieces to
catch on one another, forming a sort of lattice. The air spacethus createdtends
to negate weight difference between the shredded corrugated and Polystyrene
as well as reduce the required volume of packaging material.

Shredded paper:

Another form of loose fill consists of using shredded paper enclosed in
polyethylene sleeves. ModineMidwest Inc: shreds its office waste paper and
puts it into clear plastic sleeves, sealed at both‘ ends to form “sausages” This too
helps to absorb shock rather than transmit it to the product. Also the product is

' free of cushioning dust. (Levine, 1989)

Biodegradable loose fill:

Various types of bio-degradable loose fill materials have also been developed in
the last decade. These usually are starch based formulations made from corn or
wheat and dissolve completely in water (Figure 8). White biodegradable loose fill
is made from natural vegetable starch, which quickly dissolves upon direct
contact with water. The complete biodegradability makes it environmentally
friendly. This loose fill can also be colomed by using additives. At e Toy’s the toy

carton is filled with F Io-Pak Bio 8 starch loose fill. (Packaging Digest, 1999)

13

 

Figure 8: Biodegradable Loose-fill

FP International-buys denatured cornstarch, which is then mixed with water and
additives in a proprietary, water-soluble formula. After cooking the material, it is
extruded through a die, and the water evaporates as it exits the machine.
causing the starch to expand. The die shapes it into a tubular ‘8’ shape. It is then
stored for 24 hours in a hot humid environment. Then it is ready for shipment. To
increase packaging line efficiency, eToys installed two FP International bulk air
systems in 1998 as shown in Figure 9. The Bulk Air System (BAS) incorporates
overhead, large volume loose fill store bags and automated dispensing to keep
each packaging station supplied with loose fill. The BAS is fully automated and

requires no manual assistance.

 

Figure 9: The BAS dispensing at eToys. (Packaging Digest, 1999).

1.3 Comparison between Solid and Loose fill cushioning materials.

 

 

Solid Cushion

. Loose Fill Cushion

 

1. Solid Cushion can be cut/molded to

desired shape.

1. Loose fill is of a definite small shape.
It’s just dumped into the shipping

container.

 

2. Capital investment such as die
cutting tools is needed in most cases

other than foam in place.

 

2. Loose fill cushioning material is
available in market in a ready to use

form.

 

 

 

3. Once used solid cushion has to be
thrown away as some part of the

cushion may have bottomed out

3. Once used bottom cushion may be
bottomed out while side and top loose

fill can be separated and reused.

 

 

4.- Economically viable for high volume
shipments where mold costs can be

justified for large standard orders.

 

4. Economically viable for low volume
shipments and where product shape is

not standard.

 

1.4 E-Cubes :

 

This research investigated the. protective properties of E-cubes. Specifically it
measured the- shock absorbing capabilities and also the settling of products
during vibration. The material is available in'two different densities as shown in

Figures 10 a and 10 b.

A I.
/' P' ."
O ._’ L / r
, v ) F \- r ~
1‘ ~ ' H
.l‘ J ' 'i h
. D
up... ‘ K"
\‘;_4 } / __‘ ‘
‘ 3" ' r if
( \ v

F
x
i'- 5”.

\
w
.l
k
.\ ,
‘\

 

Grey High density E - Cubes Green Low density E - Cubes

Figure 10a Figure 10b

16

E-Cubes are cube shaped molded pulp products. They are made from paper
fibers and water. They are used as loose fill while-packing to protect the product
from hazards oftransportation. They absorb impact and minimize rebound that is
often found in resilient foam materials, thus reducing the shock levels the product

is subjected to.

The benefit of, using E-Cubes unlike other plastic loose fill packaging materials is
that they are environmental friendly. i.e.: being cellulose in nature they can be
easily land filled. E—Cubes are a 100% biodegradable product that is made from
only newspapers and water. Expanded Polystyrene peanuts (EPS) are a difficult
material to. E-cubes are made of recycled»paper.-Paper With high degree of

thrash is not recommended.

Starch based loose fill cushioning materials are hydroscopic and thus less
favorable for use in high humidity and high temperature regions in which the
starch biodegrades when exposedto moisture. For environmentally conscious,
the biodegradability nature of starch based loose fill makes .it a favored
cushioning material (Chonhenchob, 1994). However they are significantly high in
cost as Compared to EPS loosefill.. Because of the added cost they have not
been able to'gain a significant market share in the United States. They have
found popularity in Europe where tougher environmental legislation against EPS

loosefill offsets the cost factors.

17

1.5-HOW ARE E-CUBES DIFFERENT FROM-OTHER LOOSE PILLS?

The manufacturer of E-CUBES claims “that the shape of this Ioosefill gives them
superior energy absorbing properties; E-CUBES compress under impact and
then regain their shape. This ability to compress and reset allows E-CUBES to
continually protect the product throughrepetitiveimpacts, drops and jolts during
normal. shipping and handling unlike custom foam end caps or rigid foam

products.

. E-Cubes have been engineered with a rough. textured surface having a
contoured shape that makes them lock together. Despite the manufacturers
claims theyare not easy to dispense frbm current styles of overhead dispensers

that were designed for EPS loose fill due to the added weight :density.

Changes that need to be done when switching from regular EPS to E-

Cubes:-

1. Hopper size needsto be increased as E-cubes have a higher density and
occupy more space. So there needs to be more room in the storage

magazine from where they can be dispensed on to the'pack.

2. E—Cubes are not as slippery as other loose fill materials. The discharge

systems need to be adjusted (increased) in size.

1.6 E-CUBES DISPENSING SYSTEM

Bulk Dispensing Systems are'designed such that it provides high-speed

dispensing in limited warehouse space. All bulk systems are modular in design,

18

. which helps during expansion. The advantageof this system is as requirements

grow, additional modules can be added without discarding the existing equipment

(Figure 11).

 

 

 

 

I135

 

all. _.

__
til-1

j

as

 

r '3'!-

Figure 11: Bulk Dispensing System (wwwe—cubescom).

1.7 Current Applications of E-cubes:

 

The manufacturer ofE-cubes claims that their product is: used for a wide range

of products-in different industries that are listed: below:

Auto parts

Computer components
Consumer electronics
Musical instruments
Antiques

Liquids

Medical equipment
Mail order

Ceramics

Fixtures

Lighting

Electronics
Lubricants

. Paints

l9

,Soaps

Candles

Medical Supplies
Carved wood products

Food Baskets
Glass and cups

It may be possible to .pack the above products in E~cubes. But as of today we
find that majority of companies are. still using 'EPS peanuts as a loose fill because
of cost factors. Polystyrene peanuts come in the shape of peanuts, shells and
~ hooks. Some. of the reasons that EPS is still a widely used loosefill are:
0 The cost of Polystyrene peanuts is 80 to 90 cents per cu.ft. while that of E-
cubes is as much as $2.00 per cu.ft.
o Polystyrene peanuts can be used for a wide temperature range without
- loss of performance.

. They are generally clean and do not create any residue or dust.
1.8 E-CUBES Current Specifications:

Physical Description
Size 1” x 1” x 1" cube
Composition Recycled newspaper and corrugated cardboard
Weight 1lblft3 (dependant on raw materials)

Colour Green, with most colours available by special order

1 Uses

E-CUBES are a versatile void filling and cushioning material. They
are an alternative tovirtually all-types of packing media including
styrofoam inserts, die-cut corrugated, foam-.in-place, bubble sheets,

foam packs, molded pulp, Kraft paper, etc.

Electrostatic Properties

E-CUB‘ES is intrinsically anti-static. They pass Federal Specification

7 PPP-C-1683A .for‘electrostati'c adhesion of packaging material.

They also. qualify. under the Electronics Industries Association test

-. ElA-541 as packaging for electrostatic discharge sensitive

electronic devices.

Vibration Settling (Product Migration)

When tested for vibration settling in accordance with federal
specification PPP-C-1683A, a box is tightly packed inside another
box with 3-inches of E-CUBES all-around the inner box. After a half

an hour of strong vibration, no visible settling was observed.

Humidity 8. Spill Containment Effects

E-CUBES' performance is not affected by high humidity. E-CUBES

absorb up to sixtimes theirweight to contain spills.

' Hazard Identification

Overview: E-CUBES is a green, odorless, non-toxic molded paper

product. E-CUBES, by their nature of being composed of recycled

21

.. paper, present no greater health hazard than thecardboard box in

which they are packed. -~~
Carcinogenicity: NTP - none,lARC - none, OSHA ‘- none
Potential ecological effects: none

MSDS sheets available upon request.
Industrial Consumer Recycling

E-CUBES can be recycled.
Home Consumer Recycling

E-CUBES can be recycled with other paper products. E-CUBES is

an excellent composting medium.

. (Warda; Tom, President of E-Tech‘, 1998)

1. 9 OBJECTIVES:
The literature review in this chapter clearly shows a wide range of cushioning
materials that are used for different applications. Each of‘these materials has
distinct advantages and disadvantages for a given applications. Two types of E-
Cubes are commercially-available and were tested in this study. These are the:
1. Original strength. E-cubes, which weregreen colored and have a low
density,

2. High Strength E-Cubes, which are grey colored and have'a high density.

22

The two main objectives of the study were:
-. 1. To test the shock absorbing properties of E - Cube material and develop
cushion curves.
2. To test the performance of the E-Cube material during vibration (settling of

products).

The tests were conducted using ASTM methods. The experimental design and

.data analysis are presented in the next section of this thesis.

23

CHAPTER 2': MATERIALS, METHOD, AND TESTING OF E-CUBES.

A number of organizations have worked on developing packaging test standards
in the United States. The oldest and largestis the American Society for Testing
and Materials (ASTM), committee D-10 on Packaging. Operating as a balanced
consensus group the ASTM D-10 committee has generated several hundred
packaging standards since its inception in 1914. The committee currently has
jurisdiction of over 130‘ standards published in the Annual Bock of ASTM

Standards, Volume 15.09, (www.astm.org)

2.1 Shock Test for E-Cubes:

There are two ASTM'methods that aretcurrently used to measure the shock
absorbing characteristics of cushioning materials. ASTM (D 1596 -— 97): Standard
Test Method for Dynamic Shock Cushioning Characteristics of Packaging
Materialsis generally used for materials that are solid cushions which are either
molded or fabricated for end use. In this test method rectangular samples of the
test material are used and a dropping weighted platen: is used to determine the
transmitted shock from different heights. The second method ASTM D 4168 is
used for molded foam in place cushioning materials. In this method an
instrumented block is placed inside a molded cushion which is then dropped on a
programmable shock table using different equivalent free fall drop heights to
determine cushioning properties. However there is no existing-test method that

has been developed to test loose fill cushioning properties by ASTM. In various

, test. studies and research. projects conducted by the School of Packaging,
Michigan State University‘s modified versions of ASTM D 4168 is used for loose
fill'cushioningmaterials (Chonhenchob, V., 1994, and Zesaguli, C., 1999). The
intensity of the shock felt by an instrumented test block that simulates a product
in a corrugated box is measured. The accelerometer mounted in the
instrumented test block measures the acceleration and duration. This G depends
on thertype of cushioning material used, its thickness, drop -height,and static

loading used.

The instrumented test block is a wooden box measuring 8 inches x 8
inches x8 inches-as shown in. Figure 17. The test block has provision to insert
the ballast weights. These weights: could be adjusted to get the desired static
, loading. The test was first started with low weight and then the static loadings
were gradually increased. The test block was kept flat so that the vertical
component of the impact would not be lost. Also the weights inside were
properly fastened tightly with the help of screws so that they wouldn’t collide with

each other and give readings with high frequency noise.

On the top of the ballast weight, a 10 mv/g piezoelectric accelerometer
was mounted. This was used to measure the signal from the impact. The
principle of operatidn of this type of accelerometer is based on the tendency of
certain materials such as quartz. and ceramicsvto produce a charge when
compressed. The movement of a small steel mass attached to it generates
pressure. As the mass moves in relation to the housing as a result of shock, it

places the material either in-tension or compression and causes a small electric

25

current to flow through the wires connected to either end. The voltage produced
by this device is a direct indication of the magnitude of the acceleration at every
instant. In other words the device acts, like a little battery whose voltage output is

proportional to the instantaneous acceleration.

The accelerometer was placed at the base of a square shaped metal
object for which the transmitted shock was to be measured. It was located at the
center. It was mounted parallel to the anticipated shock since it records shock
only along its axis. This accelerometer records the entire shock pulse. The signal
generated by the accelerometer was analyzed using a software package

. deveIOped by Lansmont Corporation, Monterey,'CA (Test Partner).

‘ l ; '1
.' :55 1% E .2!
‘ :j ‘1'

“i ’-
~ man
':
5
.r
'i ' .
k. -
H if
r! "
‘: it 7:,
‘ figs;
WK

 

i'“’-~.-—-~-- “' t haw» —--.

 

Figdre 12. a: Test Block

26

 

"—41.0 Potion Test: recorder

 

 

 

Ulullflllmll]

Accelerometer

 

 

 

“L 11 unnmrrun]

 

 

 

 

\

 

 

 

 

 

 

 

\Bcllost Weights

 

Figure 12. b: Schematic drawing of the Test. Block Used for Shock Test.

The instrumented test block was placed at the centre of a 12 x 12-x 12-inch,
single wall RSC style corrugated box (regular slotted container). Two inches of E
cubes were placed at the bottom and the four sides and top of the corrugated
box. The box was then closed with-a plastictape. Similarly for the three inch
thick cushioning material test, the same procedure was repeated using a 14 x 14
x 14 inch RSC corrugated box. ‘

The corrugated box with the cushioning material and the wooden test block was
restrained on a programmable shock machine as shown in Figure 14. The shock
table was then dropped on plastic programmers. The shock machine was
calibrated to perform equivalent free falldrops from 24 and 36 inches. Five

consecutive drops were made with the same cushioning material and static

27

loading. A filter of 156- Hz was used to remove the. disturbance'or noise from the

shock pulse and the peak G of the shock pulse and'duration were recorded.

 

 

corrugated
box

 

 

III]
I

111111!

 

 

 

‘1
I
In I Inn 11

 

 

 

 

 

 

 

 

 

 

 

 

 

 

/

 

. e-cubes that are being tested

Figure 13: Schematic drawing of the box Used for shock test.

The two types of E-cubes testedwere:
1. Original - Low density
2. High density E-Cubes.

Both types of loose fill materials were tested at five static loads of 0.15, 0.25,

0.35, 0.504, and 0.799 psi .The static load 6 is defined as:

o = Weight of theProduct

Area of contact

The procedure used for the data collection is summarized below:

28

A 12 x 12 x 12 inch corrugated box was taken and 2 inches thick of

cushioning material was added.

The test block was placed starting with the lowest static load.

Mbre E-cubeswere added to. fill the b0x tightly so that the test block
did not move. The corrugated boxWas then. closed using a plastic
tape.

This was placed .on the shock table with plastic programmers.
Thetable was set to perform an equivalent free fall drop of 24
inches

Fiveconseeutive drops were made.

The shock pulse was recorded and the” peak G and duration for
each impact recorded.

The above steps were repeated for all the other static loads.

The entire procedure was repeated for the 36 inch free fall drop

height.

The experiment was repeated. using a 14 x 14 x 14 inch RSC

corrugated box to measure transmitted shock properties for a 3

inch thick material.

29

 

 

Figure-14: Picture of a shock table

2.2Vibration Test for E-Cubes:

In a previous study conducted at Michigan State University, School of
Packaging (Zesaguli, 1999), a test method was developed to study the effects
of settling of products in loose fill materials due to transport vibration. In this

study three different shaped products (flat, spherical, cylindrical) were used to

30

see the effeCts of vibration on settling in various types of EPS loose fill. This

~ study found that the spherical shaped products settled the most and would be
the product of choice to conduct additional settling studies. In this study three
different spherical shaped products were selected that will be used with E-
Cubes placed in a corrugated box. The time required for the spherical
shaped object to settle a certain distance was measured while the box was
subjected to random vibration in accordance with ASTM D4728. The Truck

. Composite Power- Density spectrum was used in accordance with ASTM D

'4169. Assurance Level II. Figure 15 shows the test setup of the vibration test.

.‘P n’ ' ”"vv .

,',.'1'

 

 

Figure 15: Vibration Test

The ASTM vibration tests using the electro hydraulic vibration table simulate the

vertical vibration forces. Additional settling can also occur due to the presence of

31

 

- lateral and‘longitudinal forces in real life shipments. Real life shipments have
both lateral and longitudinal vibrations along with the vertical vibrations
(Pichy-angkura, 1993)

This‘study was done to. evaluate the settling behaviour of the loose fill cushioning
during transportation. An electro hydraulic: vibration table was used in the
vibration test. Thermovement of the vibration table is achieved by high-pressure
hydraulic fluid placed in a pistons/cylinder arrangement. The fluid is set in motion
by a. servo-valve, which is controlled by an electrical signal. The valve releases
the fluid in step withelectrical signal.

The ASTM vibration tests using theelectro hydraulic vibration table are more
expensive as compared to the old rotary vibration tests due to the high cost of
the equipment. The vibration table produces vibration movement restricted in the
vertical orientation since accelerations in the vertical orientation are the highest

compared to the accelerations experienced in the other orientations.

The three types of spherical objects used in this study are described and shown
below:

1 Pool Ball (Diameter = 2.5 inches, Weight 169 g)

2 Croquet Ball (Diameter = 3.0 inches, Weight 185 g)

3 Wax Ball (Diameter = 4 inches, Weight 389 g)

A 12 x 12 x 12' inch corrugated box was half'filled with E-cubes. A thread was
tied to the spherical object, and was passed through 'two holes on top as shown

in the Figure 16. The idea was tokeep the thread straight and. measure only the

32

' penetration-ofthe pool ball with time. The flaps of the corrugate box were kept
erect. A piece of board was put above it through which the thread passed and
came out of .the V: Shaped construction on top. This kept the thread straight so
as to reduce error due to thread slack. The thread was pre-marked in the case of
distance - controlled vibration and was unmarked in the case of time - controlled

vibration measurements.

 

. Figure 16: Settling TestUsing Random Vibration.

2.2.1 Distance Controlled Vibration Study:

In this test, the ball was tied to a thread, which was marked at an interval of 1
inchfor a total of 6 inches. The time for penetrating each inch was recorded
for each type of spherical object. The data showed the difference in settling of

the object.

33

. Figure 17 shows the croquet ball‘before the vibration test and Figure 18

shows it after ithas settled in the loose fill due to vibration.

 

Figure 18: The crocquet ballafter the vibration study.

Similarly, Figures 19 and 20 show the other two types of spherical balls used in

the settling vibration tests.

34

 

Figure 20: The Pool ball used in the vibration study.

2.2.2 Time Controlled Vibration Study:
In this second type of settling test, the table was set to produce random
vibration in accordance with ASTM D 4728 using the truck spectrum. Every

15 seconds, the amount of settling of the thread (spherical object) into the

35

corrugated box was measured for a totalof 15 minutes or 6 inches of thread
travel, whichever occurred first. New corrugated boxes and unused E- Cubes

. were used for all the above settling tests.

36

CHAPTER 3: DATA ANALYSIS“ AND RESULTS

3.1 Transmitted Shock Data:
The transmitted shock data collected for the 2 and 3 inch thick E-Cubes is
shown in Tables A-1 to A-8 for both original and high strength samples. These
tables show the raw datacof peak acceleration GM)( and shock duration as
collected in the laboratory. Five sequential drops were performed at each of the
five different static loadings.
Static Loading (S.L) is calculated as:

S.L = Product Weight
Cushion 'Area

 

A-cushion curve is a graphof the peakideceleration Gmax of the product on Y-
axis versus static loading on X — axis for a giventhickness of material, and dr0p
height.

During an impact, the cushioning material absorbs the shock-as much as it
can by virtue of itsnature and thickness and the remaining is transmitted to the
product. The thicker the loose fill used, the better the performance. But not all the
loose fill materials are able to keep the shock level ‘G’ to a lower value even if a
large amount of cushioning material is used (Singh, et al, 1994).

The shapes of conventional cushion curves for cushioning materials slope
down on increasing the static load, reacha point, and then increase for higher

static loadings. However the cushion curves obtained for original density and
high density E-Cubes as shown in Figures 21 to 36 do not seem to follow this

pattern. The Gm,x values were sometimes low and sometimes high and did not

37

follow a particular pattern for the five static loads. This may be due to the fact that
E-cubes: shift during the various portions of the test, and are not consistently
positioned to offer a perfect flat loading surface for the instrumented test block.
, Therefore at such conditions, where the test block is not perfectly positioned (flat
with the impacting surface), only a component of the vertical acceleration is
measured by the single-axis accelerometer. These readings are therefore lower
than the true transmitted shock values and therefore the cushion curves
developed show a wave type of behaviour as opposed to the conventional arch.
Figure 21 represents the GM” of first drop for a two inch high -density cushion,
using a drop height of 24 inches. The values of the GMax obtained in this plot are
' higher than the one’s obtained using a three inch cushion as shown in Figure 23
for same drop height. Similarly the values in both Figure 21 and Figure 23 were
much lower than average GM...x in Figure 22 and Figure 24. Similar trends can be
observed in Figures 25, 26, 27 and 28 where a drop height of 36 inches was
used, while other parameters were kept constant.
Comparing Figures 21 and 29 between high density and original density cushion,
using the same drop height of 24 inches, it is evident that the GMax in high density
is loWer than the one in original density E-cubes. The average GMax values were
not very comparable as seen in Figure 22 and Figure 30. One of the reasons
could be that the cushion material bottomed out. Similar conclusions can be

drawn for Figures 31 to 36. The various cushion curves are presented in this

section.

38

 

’ Two inches, High density cushion,
Drop height = 24 "

r—‘.—'———']

L1. First Drops'.

l
I
|
l
I
I
l
l
l
I

G Max

 

l
l
l o 2 4 e l
I ‘ Static-Load I

Figure 21: Two-inches, High- density cushion, drop height of 24inches,
‘G’Max offirst drop.

 

Two inches, High density-cushion, i
Drop height = 24" |

I

I

g 9 Average _of!
second
through fifth
'6' Max '

 

 

l
l
l , . .
l l
l| 0 0.5 1 i
j . Static Load I

Figure 22: Two inches, High-density cushion, drop height of 24inches,
Average G max

39

Three inches, High density cushion,

Drop height = 24“

 

40
35
30
25

 

20

 

G Max

15

_._-._: o Firstdrops

 

10

 

 

 

0.5 1
_ Static Load

Figure 23: Three inches, High density cushion, drop height of 24inches,
‘G’Max of first drop.

600
500
400
300
200
100

‘GMax

Three inches, High density cushion,
Drop height = 24"

 

 

 

 

 

 

w“_ u“... 0" ___ *_ _*_* ..._ h:
O'Average of
*‘ second
through fifth
'6’ Max.
n M. i..._.-_.___..__. “-W “was “—“rj
9 e
0 0.5 1
Static Load

Figure 24: Three inches, High density cushion, drop height of 24inches,
Average G max *

40

 

Two'inches, High density cushion,
Drop height = 36"

' GMax

 

0 0.5 1
Static Load

 

 

 

Figure 25: Two inches, High-density cushion, drop height of 36inches,
‘G’Max of first drop.

 

l l
l Two inches, High density cushion, '
Drop height = 36" i

l

 

 

 

500
g, 400 ..
3 ' oAverage of
5 300 ' ' second
through fifth
E 200 '6’ Max
0 100
0
0 0.5 1
Static Load
L___’__//
drop height of 36inches,

Figure 26: Two inches, High-density density cushion,
Average G max

41

Threeinches, High density cushion,
Drop height = 36"
45 ~--~~~---~— .
40 e -
35 e ——---f
30 —--—-—-—-——-j
25 -———- s
20 —3~— . — ’ e1 0 Firstdrop
15 I A P . I
10 —-—-——-———— ———-

 

 

 

 

 

 

 

 

GMax I

 

 

 

 

 

 

0 ' 0.5 1
Static Load

Figure 27: Three inches, High-density cushion, drop height of 36inches,
‘G’Max of first drop.

Three inches, High density cushion,

 

 

 

- Drop height = 36"
s 200 ._________,__,-,__,__.,,____._.__.__--______._.....
F 3
N . ‘
g 3150 _--__.__ , - -------
‘3 5 9 oAverage of
5’ .: L....__-__.-__.-_.---_--.____---...--”my“-.. -—-.- second
5 E 100 through fifth
O

2 E t '0' Max
. 5 50 -_..__.._____-_.-_._. -~--~v—J~ -~«~e~
“ l
E
0 0 —e‘

O 0.5 1

Static Load

Figure 28: Three inches, High-density cushion, drop height of 36inches,
Average G max

42

" - gTwo inches, Original density cushion,
Drop height = 24"

 

 

 

 

d, 50 {we m. 2--...-” . ---_--_. ,,_ ....--._ -,_._ -- .. w...
o .1
2 0 "
(u ___..________.._.in-..““ii”-__..__-__.._._._.__.i_-___...7
> 40 . +
a; o .
E 30 Hflfi...___u._.._._-__~___-..L_..__.~__;.__.---m_.i__._§
o ' O i .
"6 20 g .__..._-..__...__..__-.f 0 First drop
a
g 10 %
d) :
> .
< o
0 . 0.5 1

‘ : Static Loading

Figure 29: Two inches, Original-density cushion, drop height of 24inches,
‘G’Max of first drop.

Two inches, original density cushion,

 

 

 

 

 

 

 

 

- .Drop'height: 24"

,, 400 -----~
2 O l
N . O _
g . _, -
g c. 300 _- T ' 0Average of
g 2 second
- 1’ - -__. through fifth
g g 200 L '6' Max
9 o ' "7’ ’
s ” 100 ——f'
E o
g i
< 0 _ . 0 e 3

0 ' ' 0.5 1

Static Loading

Figure 30: Two—inches, original density cushion, drop height of 24inches,
Average G max

43

, Three inches, Original density cushion,
Drop height = 24"

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

80 r-»-m-~~.r...----....-.MW“_..__.-,__,_______%__ W_ --.._..-
‘ 7O . ___,:‘
60 f
'x 50
' " 4o
I E f OFirst drop
0 30 '-—-—--—.--———~——-W_.Q.._v___________«___.__________4;
20 3.- - __ w." _ m_ _____ “g
10 —- , “___~_, _________1:
0 E

O 0.2 . 0.4 . 0.6, 0.8 1
.StaticLoad

Figure 31} Three Vinches,Original-density cushion, drop height of 24inches,
‘G’Max of first drop.

Three inches, Original density cushion,
. , , Drop height = 24"

600 [~—~--—w »~~-_-vv~.-—.A———~—.~uvfl—UOO- -.~... m~”___,-, M»--~'-—--

 

 

 

 

 

 

 

 

E
5
o 500 g
c
- N o. 400 °
g 9 oAverage of
..‘: 2 300 1; second through
3: 3'3 200 ‘~-- fifth '6' Max
8 .
0 _____..-7__7--_.--r
o 0 i
0 0.5 1

' Static Loading

Figure 35: Three inchesioriginaldensity cushion, drop height of 36inches,
Average G max

44

Two inches, Original density cushion,

 

 

 

 

 

 

 

 

 

 

 

 

 

. -.,Drop‘height = 36"

60 Fm” -— ~- -~»-—-~-—~-~—~-—m——-.

. I

50 ,o__..___.-_- mm...” m- _w~..m-_-_*__w__,__m_-_..

4O ——---—-~-~~-~-————-~—— —~ «-—~ ~— mm ~~v——~V-—~~w~~—~—~

X .
w - '
(ED 30 ~~—~——-—~~-~—— 0 First drop

20 ,-_.__.._.____--.t-_--____--__-.m_-,--__,.-__:.__.m;

,0 __--__-_w.m__,_.:; W”. ......~._..

0» 1‘

O 0.2 . 0.4 0.6 0.8 1
‘ - Static Load

Figure 33: Two inches, Original-density cushion,"drop height of 36 inches,
‘G’Max of first drop.

Two inches, Original density cushion,

 

 

 

 

 

 

 

‘ Drop height = 36"

5
g 800 -~
2 ° ‘
E 600 j '0 Average of

E a } second
g g 400 through fifth
o ‘ 3 'G' Max

0 200 , *’ *

O O

3 ‘ ° .

2 0 r
<

O 0.5 1
- Static Loading

Figure 34: Two inches, original density cushion, drop height of 36inches,
Average G max

45

7O

60’

50
4o
30
20

’ GMax

10 ~

- Three inches, Original density cushion,
DrOp height = 36"

--H_ “..‘“wmw—WO—U—I

w

 

° 9 _° First drop

 

O 0.2 0.4 .. 0.6 0.8 1

Static Loading

F igure ‘35: Three inchesOriginaldensity cushion, drop height of 36inches,
‘G’Max of first drop.

G Average from 2nd thru 5th
drop

Three inches, Original density cushion,

 

 

 

 

 

 

 

 

Drop height = 36"

800 -— -~-~—--.

600 ‘ "‘ “ faverag'e‘of
. second

400 ‘ through fifth
V , o :97 Max

200 9 “f

0

- o
0 g
0 . 0.5 1
Static Loading

__ ‘_._ __.¥-_,_ ___ .

figure 36: Three Incheusuongmaldensny cushion, drop height of 36inches,
Average G max

46

Some general observations that can be made from the data in Figures 21 to 36

are:

1. ‘G’Max of the first drop is significantly lower than the ‘G’Ma.x of the average

from 2"d to 5th drops.

2. ‘G’M,x of high strength material is lower than that of original strength E-

cubes, but not by a large‘amount.

3. ‘G’Max of E-cubes. is higher than the values of ‘G’MaX for EPS loose fill
tested under similar conditions. (Zesaguli,1999)

4. These points were plotted .to get a cushion curve, but the values were
scattered all over; hence, a true cushion curve could not be developed.

This suggests the inability of the material to produce repeatable results

like other loose fill materials.

3.2. Discussion of Random Vibration tests:

Tables 81 to 86 represent the raw data collected for the time-controlled vibration
tests for 15 minutes each. Tables B7 to B12 represent data for distance-
' controlled vibration tests. Both these methods are discussed in Chapter 2. While
conducting the distance controlled vibration it was seen that whatever settling
occurred, it took place within the first 15 minutes. So it was decided to closely
observe the migration of the different sizes of spherical balls at an interval of 15

. seconds for a maximum. of 15 minutes. The-three types of objects used were: -

0 Pool ball of diameter 2.5 inches and weight 169 g.
- Croquet ball of diameter 3.0 inches and weight 185 g.

0 Wax ball of diameter 4.0 inches and weight 389 g.

47

It was observed that within the first few minutes the loose fill formed a type of
interlocking, that slowed and prevented further settling. Also since the E—Cubes

have arough exterior, they do not slip very-easily and further help in interlocking.

ln distance'controlled vibration, the pool ball being of‘smaller made its way to the
bottom of the loose fill quicker than the other two spherical balls of 3.0 and 4.0
inches. In time controlled vibration, the distance travelled by the three types of
balls, were compared between original and high strength E — cubes in Figures
42, 43, and 44. Figure 45 compares the distances travelled byall three balls. It
can be seen that the ball of 4 inches diameterdoes not travel very much into E-
cubes; as compared to the other two balls of diameter 2.5 and’3.0 inches. It could
also be seen in the time-controlled vibration tests that the pool ball migrated up to
8 cm as did the croquet ball. But the blue wax ball could go only 2.5 cm. This is
true even for high strength E-cubes as shown in Figure 46. The overlap of the
two curves on one another shows that the two balls of diameter 2.5 and 3 inches

travel at almost the same rate into E-cubes. ln original strength E-cubes the

objects travel quicker than in high strength E-cubes.

, Migration of 2.5 inches diameter Pool ball in two different ypes of loose fill

When comparing the data of the 2.5 inch pool ball collected for E-Cubes in this
study to that of the same ball using the EPS materials in a previous study
(Zesaguli, 1999) it is evident that this material shows a better performance and

prevents settling and object travel as compared to other loose fill previous

studied.

48

This can also be seen from data on settling from the previous study compared

to that presented in Figure 37 and 42 as shown in Appendix D

(Zesuguli,1999).

Distance traveled in cm

0

POOL BALL

 

 

 

 

 

 

 

 

 

9 l

8 _

7

6 ‘* f W—FOriginal Strength
5 1 Loose fill

4 ~— —————~—— _._,; -—I—High Strength loose
3 . '__‘ ___._____g # rm 7
2 __.___._4

1 J

o i

‘2 "l, 9) ’b 9) Q 9.) ’5 9)

'.‘ a)? b- «5 Kg? ,3;th

Time in minutes

Figure 37: Distance travelled by Pool ball in Original and High strength loose fill.

Distance traveled in cm

7 7 “Blue Wax Ball

., + Original density Loose
fill

  

"‘ —I— High density Loose fill

Figure 38: Distance travelled by wax ball in Original & High strength loose fill.

49

Distance traveled in cm

6’

 

Yellow Cro-quet Ball

 

9

8

7

6 +7 Original strength
5 Loose fill

4 —I—- High strength
3 .L°°§° fill

2

l

0

6 'L 93 (b b 9 e '5 s

K '5? ‘° «5 ,9“ '3" «t3

Time in minutes

Figure 39: Distance travelled by Croquet ball in Original & High strength loose fill.

Distance traveled in cm

9) '1’ ‘J '5 ‘0 Q ‘3

Original Strength Loose fill

+ Pool Ball '

 

—l—- Yellow Cro-quet
Ball

. Blue Wax Ball

 

 

{5
'0' \br

Time in minutes

Figure 40: Distance travelled by all three objects in Original strength loose fill.

50

High Strength Loose fill -

 
  
 

__.i

1 +POOI Ball
--I— Yello Cro-Ouet Ball
Blue Wax Ball

Distance in cm

 

so (assess
5 599,5 .39.,» 5

O‘N95MONGQ

Q ,3.

Time in minutes

Figure 41.: Distance travelled by all three objects in High Strength Loose fill

51

CHAPTER 4: CONCLUSIONS

Based on the data collected in this study, the following conclusions were

reached:

. The High-DenSity E-Cubes provide better shock protection than Original E-
Cubes?

o E-Cubes show higher shock transmission as compared to EPS loose fill
previously tested.

0 ' E-Cubes show a better interlocking capability as compared to other types of

loose fill materials and prevent-objects from settling due to vibration.

0 E-Cubes are more expensive than EPS loose fill (Appendix C).

-- . Appendix «A: ShockzDATA

Table A1
Cushion Material: High Strength, Drop height: 24”, cushion thickness: 2”.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Static, , Drop Duration G Max
Loading Sequence (m sec) Value
0.15 1 18.95 26.78
2 15.35 43.23
3 13.7 ' 54.72
4 12.75 63.37
5 11.45 34.27
0.25 1 9.4 51.32
2 20.3 72.82
3 35.85 123.14
4 16.05 191.23
5 4.15 303.55
0.35 1 34.25 15.88
2 21.2 . 29.5
3 15.8 . 52.4
4 12.95 62.91
5 11.4 84.21
0.504 1 38.65 6.05
2 39.85 78.55
3 29.9 128.33
4 13.35 731.45
5 ' 31.6 ' 987.09
0.799 1 16.65 .. 47.95
2 8.4 -’ 80.36
3 9 94.47
4 7.25 103.18
5 6.6 143.94

 

 

 

 

 

 

53

Table A2 :

Cushion Material: High Strength, Drop height : 24”,.Cushion Thickness : 3”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Static Drop Duration G Max
Loading Sequence (msec) Value
0.15 ‘ . 1 19.85 27.65
2 17.95 38.02
3 15.95 46.04
4 15.05 50.55
5 15.25 53.83
0.25 1 8.2 9.8
2 20 17
3 28.12 24.83-
4 440.3 203.25
5 5.65 398.44
0.35 1 37.4 13.52
' 2 36.3 77.22
3 39.75 97.35
4 6.65 916.54
5 8 972.46
0.504 1 40.1 35.85
2 46.6 . 58.69
3 34.65 . 129.67
4 39.4 425.31
5 39.95 988.08
0.799 1 19.35 19.07
” 2 6.9 99.18
3 11.3 , 100.37
4 6.1 122.52
5 4.1 438.37

 

54

 

Table A3 :
Cushion Material : High Strength:, Drop height : 36”,Cushion Thickness 2”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

, Static , Drop Duration GMax
. Loading Sequenc ( msec) Value
~ e
0.15 . 1 22.95 32.1
2 15.05 56.74
3 13.1 75.98
4 11.6 100.66
5 13.85 112.54
0.25 1 16.65 7.05
2 31.7 31.55
3 32.35 43.55 1
4 8.6 . 71.65 9
5 12.6 20.8
0.35 1 40.15 10.98
2 5.6 17.84
3 49.55 26.11
4 11.4 36.48
. 5 48.9 88.32
0.504 1 16.9 33.23
2 1.6 152.22
3 6.95 '- 159.87
4 4.45 ' 704.65
5 7.3 886.17
0.799 1 30.3 24.55
2 9.85 98.08
3 15.25 100.07
4 6.32 120.85
5 10.25 ' 240-74

 

55

Table A4:

Cushion Material : High Strength, Drop height : 36”, Cushion Thickness 3”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Static Drop Duration G Max
Loading Sequence (msec) Value
0.15 1 24.1 35.39
2 28.95 64.04
3 28.4 67.45
4 23.6 78.53
5 40 ' 91.15
0.25 1 8.1 39.45
2 23.65 40.45
3 21.35 , 50.7
4 13.65 ‘ 91.85
5 15.3 102
0.35 1 35.4 20.73
2 11.75 75.07
3 7.1 120.74
4 5.45 188.95
5 4.95 178.73
0.504 1 35.1 18.86
2 10.3 82.49
3 8.35 100
4 12.2 144.2
5 96.15 180.91
0.799 1 13.8 21.07
2 5.9 142.6
3 4.15 201.54
4 7 147.63
5 13.2 150

 

 

 

 

56

 

 

Table A5:
. Cushion Material:

Original Strength, Drop height: 24"Cushion Thickness 2”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Static Drop Duration G Max
Loading Sequenc (m sec) Value
e
0.15 1 23 43.78
2 13 63.09
3 11.15 74.5 .
4 10.5 76.69
5 10.85 83.39
0.25 1 24.05 30.11
2 14.55 55.72
3 1.7.35 1 57.647
4 5.05 601.45
5 5.08 672.61
0.35 1 9.2 24.81
2 30.68 36.23
3 32.6 98.27
4 37.65 362.3
5 35.6 985.27
0.504 1 13.1 31.29
2 18.25 50.96
3 14.05 66.46
4 12.65 70.69
5 11.8 78.53
0.799 1 16.6 33-58
2 11.95 152.4
3 9.05 74.75
4 7.45 91-19
5 7.15 110.78

 

 

 

 

57

 

' Table A6:
. Cushion Materialz‘Original Strength, Drop height : 24” Cushion Thickness 3”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Static Drop ‘ Duration G Max
Loading. Sequenc (rm sec) Value
e
0.15 1 20.1 31.14
2 18.25 43.57
3 41.45 60.93
4 13.3 66.25
5 14.8 74.91
0.25 1 15.65 72.2
2 40.1 87.41
3 36.5 480.21
4 {39.25 ‘ 402.46
5 38.8 986.84
0.35 1 13.8 17.29
2 25.8 19.08
3 37.85 98.01
4 38.15 84.55
5 12.95 131.27
0.504 1 5 30.21
2 18.85 32.81
3 ‘ 38.75 317.06
4 ' 37.6 348.5
5 12.55 984.7
0.799 1 16.5 33.07
2 12.05 57.67
3 10.25 84.87
4 5.85 153.63
5 4.65 233.09

 

 

 

 

 

58

 

' - - Table A7:
Cushion Material : Original Strength, Drop height : 36” Cushion Thickness 2”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Static Drop Duration G Max
Loading . Sequence (m sec) Value
0.15 1 14.9 54.73
2 10.85 77.55
3 10.8 92.7
4 15.7 103
5 9.45 111.41
0.25 1 9.87 23.27
2 3.75 22 17
3 27.8 62.6
4 10.45 31.27
*5 5.3 20.5
0.35 1 6.55 13.313
2 14.6 89.03
3 8.9 939.24
4 35.85 979.69
5 29.1 981.68
0.504 1 19.95 20.61
2 15.15 48.04
3 11.45 70.29
4 8.5 120.92
5 3.35 413.92
0.799 1 27.6 23.97
2 13.35 52.5
3 8.1 102.81
4 5.3 159.33
5 4.95 190.9

 

 

 

 

59

 

'. Table A8:

Cushion Material: OriginalStrength, Drop‘ height: 36” Cushion Thickness 3”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Static Drop t Duration G Max
, Loading Sequence (m sec) Value
0.15 1 25.65 62.11
2 7.1 98.5
3 7.45 983.38
4 4.35 825.5
5 10.4 865.78
0.25 1 24.95 33.77
2 20.9 48.89
3 14.3 55.19
4 19.7 58.19
5 5.65 126.04
0.35 1 15.14 38.32
2 17.15 384.25
3 17.75 757.23
4 3.1 749.85
5 16.5 990.53
0.504 1 - 14.85 50.7
2 11.45 73.5
3 8.7 101.03
4 8 104.74
5 8.85 944.29
0.799 1 27.25 24.02
2 13.3 57.77
3 8.75 107.16
4 6.1 143.72
5 7.12 150.25

 

60

 

. - Appendix - B .- Vibration Studies

, Table B1: Time controlled Vibration
Materials Used:
. High density loose fill
I . Blue wax Ball of 4 inches diameter.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Study Duration: . 15 minutes.
Time (min) Trial 1 ' Trial 2 Trial 3 Average
(cm) (cm) (cm) (cm)
0.15 0.0 0.0 0.0 0.0
0.30 0.0 1.0 1.0 0.66
. 0.45 0.0 1.0 1.0 0.66
1.00 0.0 1.0 1.0 0.66
1.15 0.0 1.0 1.0 0.66
1.30 1.0 1.0 1.5 1.16
1.45 1.0 1.0 1.5 1.16
2.00 1.0 1.0 1.5 1.16 g
2.15 1.0 1.0 1.5 1.16
2.30 1.0 1.0 1.5 1.16
2.45 1.0 1.5 1.5 1. 33
3.00 1.0 1.5 1.5 1. 33
3.15 1.0 1.5 1.5 1.33
3.30 1.0 1.5 1.5 1. 33
3.45 1.0 1.5 1.5 1. 33
4.00 1.5 1.5 1.5 1.5
4.15 1.5 1.5 1.5 1.5
4.30 1.5 1.5 1.5 1.5
4.45 1.5 1.5 1.5 1.5
5.00 1.5 1.5 1.5 1.5
5.15 1.5 1.5 1.5 1.5
5.30 1.5 2.0 2.0 1.83
5.45 1.5 2.0 2.0 1.83
6.00 1.5 2.0 2.0 1.83
6.15 1.5 2.0 2.0 1.83
6.30 1.5 2.0 2.0 1.83
6.45 1.5 2.0 2.0 1.83
7.00 1.5 2.0 2.0 1.83
7.15 1.5 2.0 2.0 1.83
7.30 1.5 2.0 2.0 1.83
7.45 1.5 2.0 2.0 1.83
8.00 1.5 2.0 2.0 1.83
8.15 2.0 2.0 2.0 2.0
8.30 2.0 2.0 2.0 2.0

 

61

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Time (min) Trial 1 Trial 2 Trial 3 Average
(cm) (cm) (cm) (cm)
8.45 2.0 2.0 2.0 2.0
9.0 2.0 2.0 2.0 2.0
9.15 2.0 2.0 . 2.0 2.0
9.30 2.0 2.0 2.0 2.0
9.45 2.0 2.0 2.0 2.0
. 10.00 2.0 2.0 2.0 2.0
10.15 2.0 2.0 2.0 2.0
10.30 2.0 2.0 2.0 2.0
10.45 2.0 2.0 2.0 2.0
11.00 2.5 2.5 2.5 2.5
11.15 2.5 2.5 2.5 2.5
11.30 2.5 2.5 2.5 2.5
11.45 2.5 2.5 2.5 2.5
12.00 2.5 2.5 2.5 2.5
12.15 2.5 2.5 2.5 2.5
12.30 2.5 2.5 2.5 2.5
912.45 2.5 2.5 ‘ 2.5 2.5
13.00 2.5 2.5 2.5 2.5
13.15 2.5 2.5 2.5 2.5
13.30 2.5 2.5 2.5 - 2.5
13.45 2.5 2.5 .-2.5 2.5
14.00 2.5 2.5 2.5 2.5
14.15 2.5 2.5 2.5 2.5
14.30 2.5 2.5 2.5 2.5
14.45 2.5 2.5 2.5 2.5
15.00 2.5 2.5 2.5 2.5

 

62

 

Vibration Studies:
Table B2 : Time controlled Vibration.

 

Materials Used:

I High density loose fill
- ' Pool Ball of 2.5 inches diameter.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

. Study Duration: 15 minutes.
Time (min) Trial 1 Trial 2 Trial 3 Average
- (cm) (cm) (cm) (cm)
0.15 1.0 1.0 1.0 1
0.30 2.0 2.0 1.0 1.66
0.45 2.5 2.5 1.5 2.0
1.00 3.0 , 2.5 2.0 2.5
1.15 3.0 ‘ 2.5 2.0 2.5
1.30 3.0 2.5 2.0 2.5
1.45 3.0 2.5 2.52 2.66
2.00 3.0 2.5 2.52 2.66 -
2.15 3.0 2.5 2.52 2.66
2.30 3.0 ‘ 3.0 2.52 2.83
2.45 3.0 3.0 2.52 2.83
3.00 3.0 3.0 , 2.52 2.83
3.15 3.0 3.0 2.52 2.83
3.30 3.0 3.0 3.0 3.0
3.45 3.0 3.0 3.0 3.0
4.00 3.0 3.0 3.0 3.0
4.15 4.0 3.0 3.0 3.33
4.30 4.0 3.0 3.0 3.33
4.45 4.0 3.0 ' 3.0 3.33
5.00 4.0 3.0 , 3.0 3.33
5.15 4.0 3.0 4.0 3.66
5.30 4.0 3.0 4.0 3.66
5.45 4.0 3.0 4.0 3.66
6.00 4.0 3.0 4.0 3.66
6.15 4.0 4.0 4.0 4.0
6.30 4.0 4.0 4.0 4.0
6.45 4.0 4.0 4.0 4.0
7.00 4.0 4.0 4.0 4.0
7.15 4.0 4.0 4.0 4.0
7.30 4.0 4.0 4.0 4.0
7.45 4.0 4.0 4.0 4.0
8.00 4.0 4.0 4.0 4.0
8.15 4.0 4.0 4.0 4.0
8.30 5.0 4.0 4.0 4.33

 

63

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Time (min) . Trial1 Trial 2 ' Trial 3 ‘ Average
(cm) ‘ (cm) (cm) (cm)
8.45 5.0 4.0 -' 4.0 4.33
. 9.00 5.0 , 4.0 . 4.0 4.33
9.15 5.0 . 4.0 4.0 4.33
9.30 5.0 4.0 4.0 4.33
9.45 5.0 - 5.0 4.0 4.66
10.00 6.0 5.0 4.0 5.0
10.15 6.0 ’ 5.0 6.0 5.66
10.30 6.0 5.0 6.0 5.66
10.45 6.0 5.0 . 6.0 5.66
11.00 6.0 6.0 6.0 6.0
11.15 6.0 6.0 6.0 6.0
11.30 6.0 6.0 6.0 6.0
11.45 7.5 6.0 , 6.0 6.0
12.00 7.5 6.0 6.0 7
12.15 7.5 6.0 ' 7.5 7.0
12.30 7.5 6.0 . 7.5 7.0
12.45 7.5 6.0 7.5 7.0
13.00 7.5 6.0 7.5 7.0
13.15 7.5 7.5 7.5 7.5
13.30 7.5 7.5 7.5 7.5
13.45 7.5 7.5 7.5 7.5
14.00 7.5 - 7.5 7.5 7.5
14.15 7.5 7.5 7.5 7.5
14.30 7.5 7.5 7.5 7.5
14.45 7.5 7.5 7.5 7.5
15.00 7.5 7.5 7.5 7.5

 

 

 

 

 

64

 

. VibrationlStudies:
Table B3: Time controlled Vibration.

 

Materials Used:

- 4 High density loose fill
-- Cro-quet ball of. 3 inch diameter

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Study Duration: 15 minutes.
Time (min) Trial 1 Trial 2 Trial 3 Average
(cm) (cm) (cm) (cm)
0.15 1.0 1.0 1.0 1.0
0.30 1.0 1.0 1.0 1.0
0.45 2.0 1.0 1.0 1.33
1.00 2.0 1.0 1.0 1.33
1.15 2.0 1.0 1.0 1.33
1.30 3.0 1.0 1.0 1.66
1.45 3.0 1.0 1.0 1.66
2.00 3.0 1.0 2.0 2.0
2.15 : 3.0 1.0 2.0 2.0
2.30 3.0 1.0 2.0 2.0
2.45 3.0 2.0 2.0 2.33
3.00 5.0 2.0 2.0 3.0
3.15 5.0 2.0 2.0 3.0
3.30 5.0 2.0 . 2.0 3.0
3.45 5.0 2.0 3.0 3.33
4.00 5.0 3.0 3.0 3.66
4.15 5.0 3.0 3.0 3.66
4.30 5.0 3.0 3.0 3.66
4.45 5.0 3.0 4.0 4.0
5.00 5.0 3.0 4.0 4.0
5.15 6.0 6.0 4.0 5.33
5.30 6.0 6.0 4.0 5.33
5.45 6.5 6.0 4.0 5.5
6.00 6.5 6.0 5.5 6.0
6.15 6.5 6.0 5.5 6.0
6.30 6.5 6.5 5.5 6.16
6.45 7.0 6.5 5.5 6.33
7.00 7.0 6.5 5.5 6.33
7.15 7.0 6.5 5.5 6.33
7.30 7.0 6.5 5.5 6.33
7.45 7.0 6.5 6.0 6.5
8.00 7.0 6.5 6.0 6.5
8.15 7.0 6.5 ‘ 6.0 6.5
8.30 . 7.0 6.5 6.0 6.5

 

 

 

 

 

65

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Time (min) ‘ Trial1 Trialz Trial 3 Average
(cm) (cm) (cm) (cm)
8.45 7.0 6.5 6.0 6.5
9.00 7.0 7.0 6.0 6.66
9.15 7.0 7.0 6.0 6.66
9.30 7.0 7.0 6.0 6.66
— 9.45 7.0 7.0 6.0 6.66
- 10.00 7.0 7.0 6.0 - 6.66
10.15 7.0 7.0 6.0 - 6.66
10.30 7.0 7.0 6.0 6.66
10.45 7.0 7.0 6.0 6.66
11.00 7.0 7.0 6.0 6.66
11.15 7.0 7.0 6.0 6.66
~ 11.30 7.0 7.0 6.0 6.66
11.45 7.0 7.0 7.0 7.0
12.00 7.0 7.0 7.0 7.0
12.15 7.0 7.0 7.0 7.0
12.30 7.0 7.0 7.0 7.0
12.45 7.0 7.0 7.0 7.0
13.00 7.0 7.0 7.0 7.0
13.15 7.5 7.0 7.5 7.33
13.30 7.5 ‘ 7.0 - 7.5 7.33
13.45 7.5 7.0 7.5 7.33
14.00 7.5 7.0 7.5 7.33
14.15 7.5 7.0 7.5 7.33
14.30 7.5 7.5 7.5 7.5
14.45 7.5 7.5 7.5 7.5
15.00 7.8 7.8 7.8 7.8

 

66

 

Vibration Studies:
.TablgB_4: Time controlled Vibration.
Materials Used:
I Original density loose fill
,I Blue wax Ball of 4 inches diameter.
Study Duration: ~ 15minutes.

rial rial 3 (cm) - Average
cm cm
0.0 . 0.0 0.0
0.0 0.
0.0 .0
0.0
1.0

.0.
..l
O0

'o'o'o'
'o'

A-A A-A—L—t—A—tAA-t
o: be
on o.)

..A
'm'cn'oi'cn'cn'cn'm‘

O)

N-A

bi'cn'cn'oi'cn'cn'cn'cn'oi'cn'm'cn'm'm'cn'cn'm'm'o'

Add-AAA—A—A-AA—LA—Au—k-A—l

.0
.0
.0
.0
.5
.5
.5
.5
.5
.5
.0
.0

N.
o
'oi'cn'cn'cnin'oi'cn'cn'm'm'm’ob'o'o'o'o’o

U'I

 

N N

O
N.
C
AAA—3.44
010101

67

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Time (min) Trial 1 Trial 2 Trial 3 ‘ Average
(cm) (cm) (cm) (cm)
8.45 2.0 2.0 1.5 1.83
9.00 2.0 2.0 1.5 1.83
9.15 2.0 2.0 1.5 1.83
9.30 2.0 2.0 1.5 1.83
9.45 2.0 2.0 1.5 1.83
10.00 2.0 2.0 1.5 1.83
10.15 2.0 2.0 1.5 1.83
10.30 2.0 2.0 1.5 1.83
10.45 ' 2.0 2.0 2.0 2.0
11.00 2.5 2.5 2.0 2.33
11.15 2.5 2.5 2.0 2.33
11.30 2.5 2.5 2.0 2.33
11.45 2.5 2.5 2.5 2.5
12.00 2.5 " 2.5 2.5 2.5
12.15 2.5 * 2.5 2.5 2.5
12.30 2.5 2.5 2.8 2.6
12.45 2.5 2.5 2.8 2.6
13.00 2.5 2.5 2.8 2.6
13.15 2.5 2.5 2.8 2.6
13.30 2.5 2.5 2.8 2.6
13.45 - 2.5 2.5 , 2.8 2.6
14.00 2.5 2.5 2.8 2.6
14.15 2.5 2.5 2.8 2.6
14.30 2.5 2.5 2.8 2.6
14.45 2.5 2.5 2.8 2.6
15.00 2.5 2.5 2.8 2.6

 

 

 

 

 

 

 

68

 

Vibration Studies:
Table Bt5: Time controlled Vibration.

Materials Used:

I Original density loose fill

I Pool Ball of 2.5 inches diameter.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Study Duration: 15 minutes.
Time (min) Trial 1 Trial 2 1 Trial 3 Average
’ (cm) (cm) (CM) (cm)
0.15 1.0 1.0 1.0 1.0
0.30 1.0 1.0 1.0 1.0
0.45 2.0 2.0 2.0 2.0
1.00 2.0 2.0 2.5 2.16
1.15 2.0 2.0 2.5 2.16
1.30 2.0 2.5 2.5 2.33
1.45 2.0 2.5 2.5 2.33
2.00 2.0 2.5 2.5 2.33
2.15 2.0 2.5 2.5 2.33
2.30 2.0 2.5 2.5 2.33
2.45 2.0 ' 2.5 . 2.5 2.33
3.00 2.0 - 2.5 2.5 2.33
3.15 2.0 2.5 2.5 2.33
3.30 2.0 2.5 2.5 2.33
3.45 2.0 2.5 2.5 2.33
4.00 2.0 2.5 2.5 2.33
4.15 3.0 2.5 3.0 2.83
4.30 3.0 3.0 3.5 3.16
4.45 3.5 3.0 3.5 3.33
5.00 3.5 3.0 3.5 3.33
5.15 3.5 3.0 3.5 3.33
5.30 3.5 3.0 3.5 3.33
5.45 3.5 3.0 3.5 3.33
6.00 3.5 3.0 3.5 3.33
6.15 3.5 3.5 3.5 3.5
6.30 3.5 3.5 3.5 3.5
945 4.0 3.5 4.0 3.83
7.00 4.0 3.5 4.0 3.83
7.15 4.0 3.5 4.0 3.83
7.30 4.0 3.5 4.5 4.0
7.45 4.0 3.5 4.5 4.0
8.00 4.0 4.0 4.5 4.16
8.15 4.0 4.0 4.5 4.16
8.30 4.0 4.0 4.5 4.16

 

 

 

 

 

 

69

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Time (min) Trial 1 Trial 2 . Trial 3 Average
(cm) (cm) (cm) (cm)
8.45 4.0 4.5 4.5 4.5
9.00 4.0 5.0 5.0 4.66
9.15 7.0 6.0 6.5 6.16
9.30 7.0 6.0 7.0 6.66
9.45 7.0 6.0 7.0 6.66
10.00 7.0 6.0 7.0 6.66
10.15 7.0 6.0 7.0 6.66
10.30 7.0 6.5 7.0 6.83
10.45 7.0 6.5 7.0 6.83
11.00 7.0 6.5 7.0 6.83
11.15 7.0 6.5 7.0 6.83
11.30 7.0 7.0 7.0 7.0
* 11.45 7.0 7.0 7.0 7.0
12.00 7.0 7.0 7.0 7.0
12.15 7.0 7.5 7.0 7.16 '
12.30 7.0 7.5 7.0 7.16
12.45 7.0 7.5 8.0 7.5
13.00 7.0 7.5 8.0 7.5
13.15 7.5 7.5 8.0 7.66
13.30 7.5 7.5 8.0 7.66
13.45 7.5 7.5 8.0 7.66
14.00 7.5 7.5 8.0 7.66
14.15 8.0 8.0 8.0 8.0
14.30 8.0 8.0 8.0 8.0
14.45 8.0 8.0 8.0 8.0
15.00 8.0 8.0 8.0 8.0

 

70

 

Vibration Studies:
Table B6: Time controlled Vigation.

. Materials Used:

I Original density loose fill

I Croquet Ball of 3 inches diameter.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Study Duration: 15 minutes.
Time (min) Trial 1 Trial 2 Trial 3 Average
(cm) (cm) (cm) (cm)
0.15 0.0 0.0 0.0 0.0
0.30 0.0 1.0 0.0 0.33
(T45 1.0 1.0 1.0 1.0
1.00 1.0 1.0 1.0 1.0
1.15 1.0 1.0 1.0 1.0
1.30 1.0 1.0 1.0 1.0
1.45 1.0 1.0 1.0 1.0
2.00 1.0 1.5 1.0 1.16
- 2.15 1.0 1.5 1.0 1.16
2.30 2.0 1.5 2.0 1.83
2.45 2.0 1.5 2.0 1.83
3.00 2.0 1.5 2.0 1.83
3.15 2.0 1.5 2.0 1.83
3.30 2.0 2.0 2.0 2.0
3.45 2.5 2.0 2.5 2.33
4.00 2.5 2.0 2.5 2.33
4.15 2.5 2.0 2.5 2.33
4.30 2.5 2.5 2.5 2.5
4.45 2.5 2.5 2.5 2.5
5.00 4.0 2.5 2.5 3.0
5.15 4.0 2.5 2.5 3.0
5.30 4.0 2.5 2.5 3.0
5.45 4.0 2.5 2.5 3.0
6.00 4.0 3.0 3.0 3.33
6.15 4.0 3.0 3.0 3.33
6.30 5.0 3.0 3.0 3.66
6.45 5.0 3.0 3.0 3.66
M 5.0 3.0 3.0 3.66
7.15 5.0 4.0 4.0 4.33
' 7.30 5.0 4.0 4.0 4.33
7.45 5.0 4.0 5.0 4.66
8.00 5.0 4.0 5.0 4.66
8.15 6.0 4.0 6.0 5.33
8.30 6.0 5.0 6.0 5.66

 

71

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Time (min) Trial 1 Trial 2 Trial 3 Average
(cm) (cm) (cm) (cm)
8.45 6.0 5.0 6.0 5.66
9.00 ‘ 6.0 5.0 6.0 5.66
9.15 6.0 6.0 6.0 6.0
9.30 6.0 6.0 6.0 6.0
9.45 6.0 6.0 6.0 6.0
10.00 6.0 6.0 6.0 6.0
10.15 6.0 6.0 6.5 6.16
10.30 6.0 6.0 6.5 6.16
10.45 6.0 6.0 6.5 6.16
11.00 6.0 6.0 6.5 6.16
11.15 6.0 6.5 6.5 6.33
11.30 6.0 6.5 6.5 6.33
« 11.45 6.0 6.5 6.5 6.33
12.00 6.0 6.5 6.5 6.33
12.15 6.0 6.5 6.5 6.33
12.30 6.0 6.5 6.5 6.33
12.45 6.0 6.5 6.5 6.33
13.00 6.0 6.5 6.5 6.33
13.15 6.0 6.5 6.5 6.33
13.30 7.0 6.5 7.0 6.83
13.45 7.0 6.5 7.0 6.83
14.00 ' 7.0 6.5 7.0 6.83
14.15 7.0 7.0 7.0 7.0
14.30 7.0 7.0 7.0 7.0
14.45 7.0 7.0 7.0 . 7.0
15.00 7.0 7.0 7.0 7.0

 

72

 

Table B-7
. Distance controlled Vibration Data
2.5 inches diameter Pool ball

Original density E-cubes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Trial 1 » Trial 2 Trial 3

Distance Time Distance Time Distance Time
Inches Inches Inches

1 0.00.5 1 0.00.17 1 0.00.6
2 0.00.6 2 0.01.2 2 0.00.19
3 0.02.49 3 003.17 3 0.02.30
4 0.19.20 4 0.14.59 4 0.03.20
5 1.35.45 5 0.17.29 5 0.06.30
6 1.45.20 6 0.18.38 6 0.07.40
6.5 3.00.00 6.5 NA 6.5 N/A

7 7 0.19.30 7 0.20.52
8 8 0.20.40 8 0.25.55
9 9 0.24.11 9 0.39.54

 

 

 

 

 

 

 

Table 38

Distance controlled Vibration Data

2.5 inches diameter Pool ball

High Density E-cubes

 

 

 

 

 

 

 

 

 

 

 

 

 

Trial 1 Trial 2 Trial 3

Distance Time Distance Time Distance Time
Inches Inches Inches

1 0.00.8 1 0.00.8 1 0.00.25
2 0.00.17 2 0.00.16 2 0.00.45
3 0.00.30 3 0.00.32 3 0.04.24
4 0.03.17 4 0.35.44 4 0.10.51
5 0.03.39 5 0.45.39 5 0.36.11
6 0.03.53 6 0.58.15 6 1.05.48
7 0.04.07 7 1.22.16 7 1.27.06
8 0.04.13 8 1.47.12 8 1.43.30
9 2.00.00 9 1.51.43 9 1.46.32

 

 

 

 

 

 

74

 

Table B-9

Distance controlled Vibration Data

3 inches diameter Yellow crocket ball

Original density E-cubes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Trial 1 Trial 2 Trial 3

Distance Time Distance Time Distance Time
Inches Inches Inches

1 0.00.42 1 0.00.15 1 0.00.30
2 0.01.58 2 0.01.12 2 0.01.57
3 0.02.14 3 0.02.30 3 0.08.55
4 0.07.26 4 0.02.55 4 0.10.08
5 0.08.55 5 003.00 5 0.11.58
6 0.09.45 6 0.03.49 6 0.14.28
7 0.26.20 7 0.09.51 7 0.20.22
8 0.32.47 8 0.1226 8 0.27.32
9 1.10.15 9 0.25.35 9 0.31.02

 

75

 

Table B-10
Distance controlled Vibration Data
3 inches diameter Yellow crocket ball

High Density E-cubes

 

 

 

 

 

 

 

 

 

 

 

 

 

Trial 1 Trial 2 Trial 3

Distance Time Distance Time Distance Time
Inches Inches Inches

1 0.00.20 1 0.00.28 1 0.02.28
2 0.01.10 2 0.00.47 2 0.05.42
3 0.05.49 3 0.02.32 3 0.16.00
4 0.25.27 4 0.03.25 4 0.28.04
5 0.27.23 5 0.04.39 5 1.05.23
6 0.29.32 6 0.10.11 6 1.12.35
7 0.43.31 7 0.11.59 7 1.14.52
8 0.52.20 8 0.32.52 8 1.47.58
9 1.30.54 9 0.36.52 9 2.50.33

 

 

 

 

 

 

76

 

 

Table B-11

Distance controlled Vibration Data

4 inches diameter Blue Wax ball

Original density E-cubes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Trial 1 Trial 2 Trial 3
' Distance Time Distance Time Distance Time

Inches Inches Inches

1 0.00.28 1 0.00.49 1 0.00.25
2 0.01.02 2 0.02.26 2 001.00
3 0.05.09 3 0.03.31 3 0.01.17
4 0.06.10 4 0.03.55 4 0.05.15
5 0.3014 5 0.04.00 A 5 0.06.16
6 1.18.22 6 0.04.24 6 0.08.19
7 1.38.20 7 3.00.00 7 0.12.58
8 3.00.00 8 8 2.16.06
9 9 9 2.32.29

 

77

 

 

Table B-12

Distance controlled Vibration Data

4 inches diameter Blue Wax ball

High Density E-cubes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Trial 1 Trial 2 Trial 3

Distance Time Distance Time Distance Time
Inches Inches Inches

1 0.01.21 1 0.00.53 1 0.01.12
2 0.05.40 2 . 0.05.20 2 0.01.34
3 0.20.25 3 0.08.59 3 0.03.01
4 0.23.22 4 0.14.10 4 0.09.11
5 0.26.30 5 0.30.59 - 5 1.11.45
6 1.45.25 6 0.33.20 6 1.12.23
7 1.50.13 7 0.34.22 7 1.13.20
8 2.00.50 8 0.36.23 8 1.14.18
9 2.05.20 9 0.41.16 9 2.14.52

 

 

 

 

 

 

 

 

78

 

 

 

APPENDIX C

' (E-mail : Larry Goers, 09 Nov 2000)

PACKAGING COST COMPARISON

Prepared for Artiquities

Results of the repack done by Larry Goers on Package received on 10-18-00.
Prices for materials are taken from U-Iine distributor catalog.

Using Your current Packaging Method

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Material Amount per Multiplied Cost per Unit Cost per Box
Box by
Inner Box 1 X $1.18 ea = $1.18
Outer Box 1 X $1.18 ea = $ 1.59
Peanuts 1.2 cubic feet X $0.87 cubic foot = $ 1.04
Foam Plank 4.7 feet @ 1’ x X $0.50 foot = $ 2.35
24’ Wide
Bubble Wrap 4.0 feet @ 1/2’ X $0.38 foot = $ 1.52
)_( 24” Wide
Packaging 4 minutes x $10.20 per hour = $ 0.68
Labor
Total Current = $ 8.36
Cost
Using E-cubes instead
Material Amount per Multiplied Cost per Unit Cost per Box
Box by
E-cubes 2.15 cubic feet X $2.00 ea = $ 4.30
Box 1 X $1.54 ea = $ 1.54
Packing Labour 45 seconds X $10.20 per hour = $ 0.13
Other Benefits Total cost using = $ 5.97
- E-cubes reduce/eliminate any E-cubes
breakage/damage Your savings per = $ 2.40
- E-cubes reduce packaging time box with E-cubes

tremendously
- E-cubes are recyclable

- E-cubes reduce international packaging

tariffs associated with plastics.

 

 

If you pack

 

400 boxes per
week

 

Using e-cubes your savings per week = $ 958.60
'Or per month = $ 4,153.93
Or per Year = $ 49,847.20

E-tech products inc - 4975 Paris Street Denver, Colorado 80239 - (303) 373 —
0200 FAX, www.e-techproducts.com

79

 

 

APPENDIX-D

 

0 Low
Density
ISOPACK

EPS Loose
Fil

A "Small :-
sha ed
EPS Loose
Fill

Distance (in)

—power
(Low
Density
ISOPACK )

 

 

 

 

 

O 3 6 9 12 15 EPS Loose
Time (mins) P111)
Figure F2:Migration Distance of Spherical
Ob1eCt.

Figure 42: Distance travelled by the Poll ball in EPS

POOL BALL

 

 

9 H n ,. .v
E 7 fl w—eeAe— 7* ‘
E 6 7’" "" r“: ‘ ,7; —O--Original Strength
E 5 A- w. » —— h ’ a- ,_ We: Loose fill
g 4 —~‘-‘*'* - ——'——" +High Strength loose
8 3 ‘ -__- -1 rm
: ,
g 2
a 1
0

 

6: b ‘3 ‘3 b to b ‘3 9: (o
N N N N N h
..‘.» ,5. ,i- Q, ,rq.\°r\.,.o.

Time in minutes

Figure37: Distance travelled by Pool ball in E-Cubes.

8O

LIST OF REFERENCES

Charnnarong, Noppom.”on a comparison between various package
cushioning materials based on perfonnanoe and environmental concerns”,

Masters Thesis, School of Packaging, Michigan State University, 1991

Chonhenchob,Vanee.”on a comparison of various Packaging loose fill
cushioning Materials based on protective performance and environmental

concerns”, Masters Thesis, School of Packaging, Michigan State

University, 1994.

Levine Norman, 1989, http:IIWeb.indstate.edulrecycI919608.htrnI

Packaging Digest, , “Misting Starch foam molds protective cushioning". pp

68, April 1997.

Packaging Digest, , “Kid-friendly starch loose fill helps e-toys fill Santa’s

Orders.” pp 62, December 1999.
Packaging World, ”Practice makes perfect’, pp 26, July 200.
Pain,F.A., “Fundamentals of Packaging’ 1967,pp 21

Papermart, 2000, http:/Mwwpapermartcomlhomehtm

Pichyangkura, Atiwadee. “ On Comparison of Various ASTM and NSTA
vibration Test methods for product Packaging”, Masters Thesis, School of

Packaging, Michigan State University, 1993.

81

Singh. P., Chonhenchob,V., Burgess, G., ”Comparison of Various Loose-
fill Cushioning Materials Based On Protective and Environmental

Performance’ Packaging Technology and science, pp 229 —241, 1994)

Singh. P., Chonhenchob,V., Burgess, G.,“A Comparison Between Various
Cushioning Materials.”pp28, lopp Technical Journal Winter 1992.
Rogers, Encyclopedia of Packaging, pp343, Wiley’s Encyclopedia, 1986.

United Parcel Service “Interior Packaging Components, Packaging for the

Small Parcel Environment “pg 89 - 90

Warda, Tom, President 'of E-Tech, 1998, http://www.e-cubes.com

Zesaguli, Maud Constance.”Comparison of Loose-fill Cushioning Materials
for Shock Absorption Capabilities and Settling During Vibration,” Masters

Thesis, School of Packaging, Michigan State University, 1999.

82

 

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