P&G – GLOBAL INNOVATION AT SCALE (Part 1)

Before founding ARNE.STUDIO, I spent 15 years at P&G, working across multiple business units utilising the largest scale packaging technologies. I had the opportunity to engineer designs for multi-billion-dollar global brands which are still some of the most recognised packs on shelf today.

As a Principal Engineer (Technical Director), I managed packaging development innovation pipelines for Home Care, Fabric Care, Hair Care and Fine Fragrance. I initiated new platform technologies, and launched digitisation and digital twin workflows specialising in automation and visualisation.

Below are some of the projects I worked on:

Ariel Liquid Detergent

  • EBM bottle development
  • After 10 years in the market, this remains one of P&G’s flagship hero packaging formats sold globally
  • Label panel design
  • Design for stability
  • Pallet optimisation
  • Plastic weight reduction
  • CAD automation
  • FEA validation
  • Consumer testing & prototyping
  • Supplier management
  • Parison design with visual strip

Flash Multi Surface Cleaner

  • ISBM bottle development with IM multi-component dosing cap
  • Gold award-winning compaction initiative for EU markets
  • Low-cost, reliable mechanism development
  • ISBM preform design (1-step and 2-step compatible)
  • Visualisation
  • Rigid body packing line validation (automated validation)
  • Refinement through prototyping
  • 3D printing
  • Unit cavity mould design
  • Volumetric automation
  • ISBM push-up development

Surfstick & Swiffer Refill Spray Mop

  • Multi-component, multi-material, IM and BM device development
  • Worked on multiple SKU’s, across the Swiffer range. In some cases, the bottle was replaced after use, while in others, the cleaning pad is the consumable component
  • Devices contain internal mechanisms including one way product path valve solutions
  • Implementation of M&S for joint structural analysis
  • Worked extensively in China alongside manufacturers
  • Design for assembly (manufacture)
  • Self-assembly development (consumer)
  • Managed incumbent P&G R&D at the design agency (US) and then at the manufacturer (China)

Ariel Gel

  • Introduction of gel formula in a new-to-category precise squeeze-to-dose tottle
  • EBM tottle
  • Squeeze characteristics optimisation 
  • Parison design with visual strip
  • Over-moulded two-shot doser
  • Shape iteration for filling line stability
  • UK based unit cavity production for BASES tests
  • DOX shape optimisation with FEA validation loop
  • Puck filling line (for tottle shape)
  • Post launch cost saving initiatives (Silicone>TPE valve, TPE>PP over-mould)

Fairy Dish Care

  • Iconic Fairy bottle sold across brands worldwide
  • One of P&G’s longest-running, most recognizable and most efficient designs for both pack production and fill line operation.
  • Preform light-weighting
  • Feature analysis with FEA validation
  • Rib & feature design for bottle strengthening 
  • Multi-Size line up expansion
  • Lable panel optimisation
  • 2D Artwork Technical Design specification
  • Visualisation

Pantene Large Sizes

  • Pantene pouch redesign for Asia markets
  • Developed while based in Singapore
  • Initially launched with an aluminium layer (vertical start up, speed to market) but costs optimised to include recyclable mono PE
  • Parametric CAD-based volume prediction tool development
  • Top-fill and seal production line change part design
  • Single-use execution (with integrated pre-sealed spout and cap)
  • Refill execution (without IM components for dispensing into a secondary delivery system)
  • Drop tests and squeeze/burst tests for seal strength validation

Air Assist

  • Diamond award winning e-commerce pack
  • Innovative inflatable air ribs result in bottle like performance with benefits of flexible packaging
  • Breakthrough in performance and sustainability
  • 50% less plastic than rigid equivalent
  • Integrated valve produced with laminate alone (no additional components/materials)
  • Single handed clean dispensing with controlled dosage
  • Amazon ISTA 6 approved for ecommerce distribution.
  • Interzero ‘made for recycling’ certification
  • The production of this pack is based on a patented Form, Fill, Seal conversion line developed, manufactured and validated inhouse at P&G.
  • Production line change parts are parametrically redesigned based on changes to the pack geometry.
  • Revolutionary air frame flexible bottle

EcoClick Laundry Capsule Tub

  • Plastic free cardboard replacement for current vac formed plastic tub with IM rim/lid
  • The structural design was almost complete when I started work with this initiative however there were issues with the artwork caused by the cover and base which can move independently
  • 3D Tolerance analysis looking at effects of artwork misalignment
  • 2D Artwork templatization work to ensure widest window of operation
  • Pack Visualization
  • 2D > 3D artwork validation tool development

Want to see more ?