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BPO, we know how

BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

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Page 1: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

BPO, we know how

Page 2: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

BPO, D

elft

BPO, we know how

Page 3: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

BPO

How to get from ideas and concepts to realised plastic parts? How to save on material costs? How to combine plastic with metal intelligently and skilfully? How to shorten the time to market for innovative products?

Experience shows that the answers to these questions are brought much closer by working with BPO (Delft, the Netherlands). The BPO team consists of both designers and specialised engineers. Together they develop and optimise products, aided by advanced computer analysing techniques. BPO supports and executes the complete product development process: from first sketch to production. BPO: twenty-five years of experience and know-how in product development and engineering.

DevelopmentYou have a great idea, but little or no experience in the development of plastic products. You lack the capacity in your own company or you just want an optimised product…

BPO is more than willing to be involved in the development starting with your first sketch. This stage already calls for several important questions to be answered. Can the product function with fewer parts? Which materials and which production methods are suitable? How strong or stiff should the product be? Is it safe and what is its life expect-ancy? How much does the product cost and can it be produced more cheaply? How can a better air, gas or fluid flow improve the performance of your product?

Like no other, BPO is capable of predicting at an early stage the consequences of certain design choices for the final product. This insight saves a lot of time and prevents expen-sive changes late in the development cycle. BPO arranges brainstorm sessions to generate ideas for you. Insight in the appearance of your product is given with 3D visualisation. The economic and technical feasibility is assured by comprehensive studies. BPO initiates and supports innovation. In

trod

ucti

on

Page 4: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

One objective: your product

BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in all our work is our direct and hands-on approach. This is appreciated by companies of all sizes.

In the end the most important aspect is always the cooperation between people that speak the same language. With one common objective: an optimal end result. BPO communicates intensively. Not only in person but also by using the internet, so that wherever you are located, BPO keeps you up to speed on the latest developments in the project and on the status of your product designs.

PeopleSince being founded in 1987, BPO has combined the skills of engineers specialized in all different aspects of product development, including design, construction and manufac - tu ring. A growing number of clients profits from the multi-disciplined approach of BPO. The team is continually expanding and currently has the responsibility for projects all over Europe and indeed around the world.

ResourcesBPO has a number of advanced tools at its disposal, to be able to perform our professional services effectively. The tools are used to develop complex products and to answer difficult questions. BPO's engineers use multiple 3D CAD programs, like SolidWorks and Creo. Analyses are conducted using advanced FEM software, capable of performing non-linear static and dynamic mechanical analyses, fluid dynamics analyses and optimisations. With Optistruct the optimal geometry based on combined loads on a product can be calculated. We have a state of the art 3D printer that can be used during development as well as a 3D scanner to create legacy data and to compare First of Tools with the 3D CAD files on which they are based. We will keep investing in future opportunities in product development to be able to give our clients the best and most complete service: creating value!

FDM 3D-printer

3D-scanner

Intr

oduc

tion

Page 5: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

01idea

02concept

03materialisation

04optimisation

05use

Serv

ices

Idea generationProblem analysis

Material selectionDesign for assembly

Concept development

Embodiment design

StiffnessStrength

CFDMoldFlow

Optimal

product

BPO services

Development &

Engineering

Analysis &

Optimisation

designgeometry

material production

Page 6: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

1 10 100 1000 10000Frequency [Hz]

Fig. 01

Fig. 02

Fig. 03

Optimal sound experience

Aut

omot

ive

D&M Premium Sound Systems has an unparalleled reputation as a world-wide developer of audio systems. Among its customers are BMW, Ford, General Motors, PSA Peugeot Citroën, Toyota and Volkswagen. BPO has assisted D&M PSS with the development of the speaker boxes in which these audio systems function. An example can be found in the design of a subwoofer box for the Citroën C5.

During the development of a new car a lot of time and energy is used to prevent unwanted noise and vibrations from getting into the car’s interior. Within the interior also a lot of attention is given to vibrations. It is unwanted that a part is rattling during a drive. This is especially important for speaker and subwoofer boxes. The vibration behaviour of these kinds of speaker housings and the interaction with their environment therefore has top priority.

The random vibrations that occur during driving can be described with a frequency spectrum. BPO has calculated the maximum displacement of the subwoofer box using a norm-based spectrum. To be able to do that, all natural frequencies and their vibration modes up to 300 Hertz were simulated.

Out of the simulations a couple of areas of concern were distilled, for instance the con- nection between the two main parts of the box. Also the connections of the subwoofer, the CD changer and the box as a whole required reinforcement. The vibration behaviour has been improved significantly by adding wall thickness and ribs on very specific spots. Next to that, BPO advised on the material choice. In combination with high end audio systems the speaker housing contributes to an optimal sound experience inside the car.

BPO

has

calcu

late

d th

e m

axim

um

disp

lace

men

t of t

he su

bwoo

fer b

ox

usin

g a

norm

-bas

ed sp

ectr

um.

All n

atur

al fr

eque

ncie

s and

thei

r vi

brat

ion

mod

es u

p to

300

Her

tz

wer

e sim

ulat

ed.

BPO

ass

ists

D&

M P

Ss w

ith th

e de

velo

pmen

tof

the

boxe

s in

whi

ch th

e au

dio

syst

ems

func

tion.

Page 7: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

Fig. 01

Fig. 02

Fig. 03Aut

omot

ive Cable Carrier

DAF Trucks has introduced the MX 12.9 liter engine. The cable carrier for this engine, guiding the cables to the electronic fuel injectors and also the guidance of the DAF Engine Break, has been developed by BPO in close cooperation with the manufacturer voestalpine Polynorm Groep.

The development of the cable carrier is a good example of state-of-the-art engineering. The limited space and special application demand a very complex geometry. Multiple film hinges are used to keep the assembly as simple as possible. It was necessary to use separate parts in some areas because of mutual tolerances and limited space. Because of this supports that can be assembled separately have been constructed around the camshaft and valve rods. The carrier is placed close to the cylinder heads where oil with a tempera-ture of 120˚C is continuously flowing through. Because of this a heat resistant glass fibre reinforced PA6 plastic has been chosen.

Simulations of the behaviour of the carrier under loading were carried out more than once during development. The cable carrier has been analysed and optimised for a number of different load cases. Special attention was given to the vibration behaviour at different temperatures. To determine the best possible injection positions and to prevent problems at the film hinges extensive moldflow analyses have been conducted. In the end the product not only provides more than adequate protection of the electronic cables during millions of kilometres but it also serves an important role during assembly and mainte-nance of different engine parts.

The

carr

ier i

s pla

ced

clos

e to

the

cylin

der

head

s whe

re o

il w

ith a

tem

pera

ture

of

120˚

C is

cont

inuo

usly

flow

ing

thro

ugh.

The

limite

d sp

ace

and

spec

ial

appl

icat

ion

dem

and

a ve

ry co

mpl

ex

geom

etry

.

Mul

tiple

film

hin

ges a

re u

sed

to k

eep

th

e as

sem

bly

as si

mpl

e as

pos

sibl

e.

Page 8: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

Fig. 01

Fig. 02

Fig. 03

Logi

stic

s Bread crate

BPO has developed a bread crate for LINPAC Materials Handling from Bad Salzuflen (Germany). In this project all aspects of the product development process have been addressed.

Using the functional requirements as put forward by the client, BPO generated different ideas in sketches and 3D CAD models. Next to that, the compatibility of the new crate with existing competing products already on the market had to be guaranteed: the mutual stackability and the dimensions had to be tuned to achieve this. A spear point during the development process was to construct the crate for a short as possible cycle time, because the crate was to be produced by injection moulding. Certain difficulties that normally characterise injection moulding, like warping because of uneven shrinking, have been overcome by subtle wall thickness differences and by using double curved surfaces in the geometry. During this development the mould construction was always in the back of our heads.

The crate has to fulfill the strictest requirements concerning deflections and stacking loads for its particular application. A starting point for this development was: minimising the material usage and the production costs. By implementing a, for this market segment unique, corner column construction as is normally used in beer crates, the crate performs equally as well as much heavier crates in its segment.The Panetto bread crate has a 5% larger inner volume compared to its predecessor, at the same time the material usage has been reduced by more than 20%! The ergono-mic and comfortable grips are another important innovation. The construction of the bottom provides the necessary stability while maintaining a distinct aesthetic appearance. All four sides of the crate have surfaces fit for printing, In Mould Labelling (IML) can also be used there.

The development of the Panetto is an example of a project where all skills present at BPO were used: form and function were integrated into the design of the bread crate, using strength and stiffness analyses together with mould flow analyses and CAD modelling.

The

crat

e ha

s to

fulfi

ll th

e st

ricte

st

requ

irem

ents

conc

erni

ng d

eflec

tions

an

d st

acki

ng lo

ads f

or it

s app

licat

ion.

A st

artin

g po

int f

or th

is d

evel

opm

ent

was

: min

imis

ing

the

mat

eria

l usa

ge a

nd

the

prod

uctio

n co

sts.

The

new

Pan

etto

bre

ad cr

ate

has a

5%

larg

er

inne

r vol

ume,

whi

le th

e m

ater

ial u

sage

has

be

en re

duce

d by

mor

e th

an 2

0%!

Page 9: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

Fig. 01

Fig. 02

Fig. 03

The

optim

al g

eom

etry

is ca

lcul

ated

for

mul

tiple

load

case

s dur

ing

the

conc

ept

stag

e of

dev

elop

men

t.

Nex

t to

stre

ngth

, stif

fnes

s, st

abili

ty a

nd

desi

gn, t

he co

sts o

f the

se p

rodu

cts i

s of

the

utm

ost i

mpo

rtan

ce.

Dur

ing

deve

lopm

ent t

he ci

rcum

stan

ces

of th

e us

e de

term

ine

for a

larg

e pa

rt th

e ca

lcul

ated

load

case

s.

Logi

stic

s Pallets, trays and crates

BPO has developed and optimised scores of products for application in logistic chains over the last 25 years. Plastic pallets, trays for bottles, plants and storage systems, crates and boxes for vegetables and fruits, car parts and technical products.

Next to strength, stiffness, stability and design, the costs of these products is of the utmost importance. The products are manufactured in very large series with very expensive tooling. To be able to develop optimal products BPO employs advanced engineering and optimisation tools. For instance, a number of boxes and pallets have been developed using Optistruct. This software calculates the optimum geometry for multiple load cases during the concept stage of development. The results of these analyses give intelligent input for the further development, where functionality, details, design and producibility are integrated into a new product.

Using these modern and advanced design tools we have been able to realise mass reduction of up to 30% and cycle time reductions of up to 45%, where the product is still robust and fit for its application.

Page 10: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

Fig. 01

Fig. 02

Fig. 03

BPO

com

bine

d CA

D e

ngin

eerin

g w

ith F

EM a

naly

ses d

urin

g th

e

deve

lopm

ent.

The

A380

conf

orm

s to

Ahre

nd’s

high

st

anda

rds w

hile

the

esse

nce

of In

eke

Han

s’ de

sign

rem

ains

inta

ct.

A sm

all n

umbe

r of p

arts

, a si

mpl

e pr

oduc

tion

proc

ess a

nd re

cycla

ble

mat

eria

ls w

ere

the

mai

n st

artin

g po

ints

for t

he d

esig

n.

Con

sum

erAhrend 380

The Ahrend 380 is a timeless contemporary design of a chair made completely of recyclable plastic; the result of a collaboration between designer Ineke Hans and Ahrend. The Ahrend 380 is light, stackable and comfortable. The main starting points for the design: a small number of parts, a relatively simple production process and recyclable materials.

The chair consists of a backrest and a seat with legs. The backrest is made of Xenoy with added recycled PET. Using the wooden models and extensive design sketches of Ineke Hans, BPO engineered the chair to a ready for production design. The different parts were built up in 3D CAD, while already considering the required production technique of injection moulding in the early stages of the development.

With extensive analyses the chair was then optimised to fulfill the strict norms and requirements that Ahrend applies to its products. The backrest has been optimised using FEM analyses to have sufficient strength, while maintaining enough flexibility especially in the top part to feel comfortable to sit on.

Designer Ineke Hans and Ahrend together have been awarded the Design Factory Prize. The Ahrend 380 chair was found to be the most successful collaboration between designer and industry for its material use, particular design, sustainability and its good use of colour. It is a collaboration that has been facilitated by the engineering and optimisation of BPO.

512

553

34,0

414

431

A

A

814

130

6230

443497

470

SECTION A-A

1

2

3

1112 7

10 89

4

13

5 6

6

wit

hout

arm

rest

wit

h ar

mre

st

Theoretic total weight: with armrests 5740[g]without armrests 5240[g]

1 - 14 seat and legs 394 093 00 394 093 00

- 1 13 armrest right 394 087 00 394 086 00

1 1 12 leg cap front right 394 099 00 394 098 00

1 1 11 leg cap back right 394 097 00 394 096 00

- 2 10 Ejot 4 x 30 PP04 DeltaPT WN5451 40 x 30

- 2 9 Ejot 4 x 16 PP03 DeltaPT WN5451 40 x 16

- 2 8 Bus 4.2 x 12.5 PP05

1 1 7 leg cap front left 394 098 00 394 098 00

1 1 6 leg cap back left 394 096 00 394 096 00

- 1 5 seat and legs drilled 394 094 00 394 094 00

- 1 4 armrest left 394 086 00 394 086 00

2 2 3 Ejot 4 x 15 PP02 DeltaPT WN5451 40 x 15

2 2 2 Ejot 4 x 20 PP01 DeltaPT WN5451 40 x 20

1 1 1 backrest 394 095 00 394 095 00

QTY QTY ITEM NO. PartName ArtNo DrawingNo size

subject

released for0-series

size

revision number

orderdrawn

date

Ahrend Produktiebedrijf Zwanenburg bv

contr.

This document is copyright of Ahrend and confidential. The contents of this document may not bereproduced either completely or in part or to be communicated externally without the writtenconfirmation of the above mentioned company. All rights reserved.

scale

released forproduction

project

date

development stage

amer.proj.

date

Zwanenburg, The Netherlands

drawn edition

drawing number

1:511-11-2011

A380 (Ineke Hans)

0150 4925

OM

A0

A380

A3

KH

512

553

34,0

414

431

A

A

814

130

6230

443497

470

SECTION A-A

1

2

3

1112 7

10 89

4

13

5 6

6

wit

hout

arm

rest

wit

h ar

mre

st

Theoretic total weight: with armrests 5740[g]without armrests 5240[g]

1 - 14 seat and legs 394 093 00 394 093 00

- 1 13 armrest right 394 087 00 394 086 00

1 1 12 leg cap front right 394 099 00 394 098 00

1 1 11 leg cap back right 394 097 00 394 096 00

- 2 10 Ejot 4 x 30 PP04 DeltaPT WN5451 40 x 30

- 2 9 Ejot 4 x 16 PP03 DeltaPT WN5451 40 x 16

- 2 8 Bus 4.2 x 12.5 PP05

1 1 7 leg cap front left 394 098 00 394 098 00

1 1 6 leg cap back left 394 096 00 394 096 00

- 1 5 seat and legs drilled 394 094 00 394 094 00

- 1 4 armrest left 394 086 00 394 086 00

2 2 3 Ejot 4 x 15 PP02 DeltaPT WN5451 40 x 15

2 2 2 Ejot 4 x 20 PP01 DeltaPT WN5451 40 x 20

1 1 1 backrest 394 095 00 394 095 00

QTY QTY ITEM NO. PartName ArtNo DrawingNo size

subject

released for0-series

size

revision number

orderdrawn

date

Ahrend Produktiebedrijf Zwanenburg bv

contr.

This document is copyright of Ahrend and confidential. The contents of this document may not bereproduced either completely or in part or to be communicated externally without the writtenconfirmation of the above mentioned company. All rights reserved.

scale

released forproduction

project

date

development stage

amer.proj.

date

Zwanenburg, The Netherlands

drawn edition

drawing number

1:511-11-2011

A380 (Ineke Hans)

0150 4925

OM

A0

A380

A3

KH

Page 11: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

Fig. 01

Fig. 02

Fig. 03

BPO

has

eva

luat

ed a

num

ber o

f ge

omet

ric sh

apes

to g

ive

the

PP

shel

ls a

stiff

rim

.

A to

polo

gy o

ptim

isat

ion

was

use

d to

ge

nera

te a

nd a

naly

se d

iffer

ent

varia

tions

on

a pa

tter

n of

gro

oves

.

Criti

cal l

oadc

ases

as i

mpa

ct b

y a

drop

on

a

corn

er w

ere

sim

ulat

ed in

diff

eren

t sta

ges

of th

e de

velo

pmen

t.Con

sum

erSamsonite S'Cure

Samsonite is market leader in luggage and aspires to sell beautiful and innovative products worldwide. The S’Cure is the lightest polypropylene travel suitcase until now. This innovative suitcase has been developed in an intensive and long-term cooperation with BPO.

Because the suitcases of Samsonite are subjected to heavy loads in different tests and because weight is of increasing importance for luggage, BPO supported the project from the start with highly advanced FEM analyses. Deformation, maximum stress and the weight of the product were constantly observed for different, mostly dynamic, loading situations. Advice has been given to improve the design and to help making choices. To be able to create a stiff and stable rim a large number of techniques and geometric shapes were evaluated during the concept phase. Also, a topology optimisation was used to generate and analyse different variations on a pattern of grooves on the surface of the shells.

To find an optimal combination between performance and weight both shells have also been optimised using moldflow calculations. Using these analyses the wall thickness distribution has been chosen to design a suitcase that can be produced within the available clamp force, while maintaining the balance between performance and weight. The largest (75 cm) version of the new S’Cure weighs only 4.5 kilograms, the smaller (69 cm) version weighs even less at 4.0 kilograms, over 20% lighter than their predecessors.

Page 12: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

Fig. 01

Fig. 02

Fig. 03

The

cons

ole

is o

ptim

ised

for p

rodu

ctio

n w

ith a

17 g

ate

hotr

unne

r with

casc

ade

inje

ctio

n.

The

sim

ulat

ion

of th

e m

echa

nica

l be

havi

our t

akes

into

acc

ount

ext

rem

e w

ind

load

s, sn

ow lo

ads,

cree

p an

d

UV

radi

atio

n.

BPO

has

use

d its

exp

erie

nce

of th

e

deve

lopm

ent o

f pla

stic

pro

duct

s tha

t ar

e su

bjec

ted

to e

xtre

me

circ

umst

ance

s.

Indu

stri

al Solar panels on flat roofs

The many flat roofs of office and commercial buildings offer tremendous potential for the installation of solar panels. For easy installation of the panels, German company SOLON introduced the SOLfixx system. BPO contributed to the development of the system with strength and stiffness analyses, moldflow analyses and the design of the wind deflector.

The SOLfixx system consists of a plastic console which can be anchored to the roof in different ways. The console is an injection moulded plastic part of 1.45 m by 2.12 m that is made in one shot. Production is done at injection moulder HSV with a 17 gate hotrunner with cascade injection that has been optimised by BPO. The location of the various injection points and when each of these has to be opened was determined. The wall thickness and flowleaders are optimised to minimise product weight at a maximum allowable clamping force of 4000 ton.

To decrease the effect of the wind loads BPO developed a special wind deflector that clicks into the console. It consists of a series of lamellae which keep the wind from getting any grip on the solar panels. The shape of the lamellae makes the wind deflector flexible. This keeps it attached to the console even if it deforms due to high winds.

The mechanical behaviour of the SOLfixx system at extreme wind and snow loads is also optimised by BPO. Because the system has to remain on the roof for over many years, the creep loads, weather influences and UV radiation have all been taken into account.

Page 13: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

Fig. 01

Fig. 02

BPO

has

ass

iste

d in

bot

h de

velo

pmen

t and

eng

inee

ring

as w

ell a

s opt

imiz

atio

n

of th

e SE

MIO

. The

mai

n co

nstr

uctio

n is

bas

ed o

n co

mpu

ter s

imul

atio

ns (F

EM)

and

a lo

ng li

st o

f req

uire

men

ts.

The

SEM

IO co

nsis

ts o

f a co

ncre

te b

ody,

whi

ch

is fi

xed

in th

e gr

ound

, and

a m

obile

5 m

3 po

lyet

hyle

ne b

ody,

whi

ch ca

n be

hoi

sted

by

was

te co

llect

ing

truc

ks.In

dust

rial SEMIO semi-underground waste system

ESE, Environmental Systems Expertise, has introduced a stationary waste and recycling container to the market. The SEMIO is a 5 m3 semi-under-ground waste system using a concrete body, which is fixed in the ground, and a mobile UV resistant polyethylene body, which can be hoisted by waste collecting trucks.

The SEMIO is perfect for all spaces with high amounts of waste. It offers a large fill volume, reduces emptying frequency and lowers maintenance costs. Only one third of the product is above street level. The SEMIO with its new straight design and all its various finish options can be integrated into many different public spaces.

BPO has assisted ESE in both development and engineering as well as optimisation of the SEMIO. The design is based on a straight shape and wide bottom opening to ensure smooth flow of waste from the container. The main construction is based on computer simulations (FEM) and a long list of requirements, which has led to a sustainable product. Individual components such as lids, various disposal openings, and three types of hoisting systems are inter-changeable. Not only does this result in specific features per customer, but also in easy maintenance which means that the products are long-lasting.

ESE always considers the entire logistic and application chain when designing products, including requirements for filling, emptying, handling, health and safety. SEMIO fulfills all current European and national standards and is certified in accordance with the European standards EN 13071.

Page 14: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

Fig. 01

Fig. 02

Fig. 03

The

shap

e of

the

keg

has b

een

optim

ised

us

ing

FEM

-ana

lyse

s, to

hav

e as

litt

le

defo

rmat

ion

as p

ossi

ble,

whi

le u

sing

as

little

mat

eria

l as p

ossi

ble.

BPO

has

eng

inee

red

all p

arts

of “

Tapj

e” to

re

liabl

e an

d ea

sy to

pro

duce

pla

stic

par

ts.

“Tap

je” i

s a u

ser-f

riend

ly h

ome

beer

tapp

ing

pack

agin

g m

ade

of P

ET. N

o ex

tra

syst

ems o

r m

ater

ials

are

nee

ded

to p

our 1

6 gl

asse

s of

drau

ght b

eer. Pac

kagi

ngParty? “TAPJE”!

Heineken has introduced “Tapje”, a light and user-friendly home beer tapping packaging made of the plastic PET. It is not just some beer packa-ging, but a unique product with a presence of its own as an innovative image carrier for Heineken and Amstel. It can be carried comfortably, is easily made ready for use and especially suitable for special occasions, like a party or barbecue. Not only the brand image and ease of use were important starting points for the development, but also efficient assembly, the resistance to pressure of the keg and a minimal use of material were of great importance. This home tapping keg is 50% lighter than its steel predecessor.

The emphasis of the contribution of BPO was on the feasibility and technical develop-ment of the most challenging part of the product: the PET-keg. The keg must not only have a relatively large content volume, but also resist the high pressure the carbon dioxide in the beer can build up.

The shape of the keg has been optimised using FEM-analyses, to have as little deforma-tion as possible, while using as little material as possible. A couple of variants have been made and tested in practice, until the final design best combined the strength and stiffness requirements with the required look of the product.

BPO has subsequently engineered the other parts of “Tapje” to reliable and easy to produce plastic parts. BPO also made all the part and assembly drawings for Heineken.

Page 15: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

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ngPackaging

Packaging is often characterised by being produced in large number and by being for one time use only. Also, the parts, often made of plastic, must comply with a whole range of requirements. This combination makes the development of good packaging a real challenge. In its 25 years of existence BPO has developed and optimised scores of packagings. Often material reductions of 10% have been achieved, cycle time reductions of several seconds and new techniques and materials have been introduced. We are always at the forefront of using the latest developments and innovations in our projects.

The results of these projects have been on the market for years now. From margarine tubs (of which yearly hundreds of millions are manufactured) to beer kegs, from aerosol caps to paint cans. A wide range of packaging designs, always as light possible, suited for its application but not a gram overweight.

Tubs are a good example of the simultaneous optimisation of strength and moldflow. Using finite element analyses first the strenght of the tub can be improved, while decreasing the amount of plastic needed per part. Next extensive mould flow analyses can be performed, improving the flow in the mould. Flowleaders in the bottom can be used, so the tub can be produced with different IML thicknesses or without IML, while retaining its favourable flow characteristics.

The weight of tubs can be reduced with several percents, while the strength remains sufficient. A balanced flow guarantees fast and reliable production and IML placing.

Page 16: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

1203004.00050.000600.0007.000.000A selection of BPO’s customers, which total to over 300:

Heineken / Unilever / ESE / Danone / Samsonite / RPC Bramlage / Villeroy & Boch / Schoeller Allibert / Dyka / BE Aerospace / Plasticum / AAF / Hollarts Kunststoftechniek / Craemer / Gizeh Verpackungen / HSV / Ahrend / Steelcase / Flamco / Zehnder Group / Ehlebracht / Haidlmair / Denios / Promens / Hettich / RK Rose+Krieger / Handicare / Ikadan / …

+25

yea

rs B

POcompany, 1 goal – your product

colleagues – from industrial designers to mechanical engineers

customers – worldwide, from small companies to Fortune 500

projects in 25 years – from small optimisations to complete series of products

tons material saved – that is 50.000.000 kg

hours cycle time saved – that is more than 300 injection moulding machines

kg CO2 saved…

Page 17: BPO, we know how · BPO is of service in a wide range of projects: from short optimisation or detailing projects to long term major development projects. The distinguishing mark in

www.bpo.nl

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