Contents

Executive Summary....................................................................................................................................... 3
Introduction .................................................................................................................................................. 4
Problem ......................................................................................................................................................... 4
Recommendations ........................................................................................................................................ 5
Recommended Design of the tray ................................................................................................................ 6
Recommended Design 1 ........................................................................................................................... 6
Figure 1: 3 Dimensional view ................................................................................................................ 6
Figure 2:Top View ................................................................................................................................. 6
Figure 3: Front view .............................................................................................................................. 7
Figure 4: Side View ................................................................................................................................ 7
Recommended Design 2 ........................................................................................................................... 8
Figure 5: 3 Dimensional view ................................................................................................................ 8
Figure 6: Top view ................................................................................................................................. 8
Figure 7: Side view ................................................................................................................................ 9
Figure 8: Front view .............................................................................................................................. 9
Recommended Dimensions ........................................................................................................................ 10
Dimensions of Recommended Design 1 ................................................................................................. 10
Dimensions of Recommended Design 2 ................................................................................................. 10
Recommended Materials for the trays. ...................................................................................................... 11
Polypropylene (PP).................................................................................................................................. 11
Toughened Polystyrene (PS) ................................................................................................................... 11
Polymethyl Methacrylate (PMMA) ......................................................................................................... 11

Acknowledgement
This short project was a different and a good learning experience for me. It built my expertise in
AutoCAD as well as gave me a practical approach to deal with problems.
I am especially thankful to Mr. Muhammad Abbas (Asst. Manager Production-Coordination) who
discussed the problem with me and gave me as a project to sort out is solution.
I am also thankful to Mr. Hamaad (Drafts man Mechanical) who helped me designing the tray.

Executive Summary
Dobala cream is being produced at EFL-SKZ plant. There is a problem going on due to its chilling process.
The paper card-board tray get wet and torn up. Almost 50% of the trays get wasted during handling and
while loading. I have designed a perforated, plastic tray which can be used to chill the Dobala cream.
I have made the design so that a strong, durable and maximum perforated box can be made. The
dimensions of the box are so that they are easy to handle as well as cost effective. I have suggested
Polypropylene (PP), Toughened polystyrene (PS), Polymethyl methacrylate (PMMA) as these materials
are durable and strong.
I am hopeful that if my designs are implemented, the problem faced now will be rectified.

Introduction
EFL SKZ plant is manufacturing Dobala Cream. Dobala is a fat rich delicious cream. After the cream is
filled in packets, the packets are placed in a paper-card board tray which accommodates 24 packets at a
time. After packing the packets in the paper-card board trays, the trays are placed in a chilling unit for
24 hours. At the end they are removed from the chiller, sealed and loaded for transportation.

Problem
When Dobala is placed in the chiller for chilling for 24 hours, a moisture layer appears on the Dobala
packets. The paper card-board trays absorb the moisture and get wet. Due to the moisture content the
trays lose its strength and get torn during sealing and loading.
Almost 50% of the trays are torn like this and the packets are to be repacked in the card-board trays and
this result in wastage of trays and valuable time.

Recommendations
Considering the loss of trays and the valuable time, a solution should be sorted out to rectify the
problem.
The root cause of the problem is the moisture layer on Dobala packet when it is removed from the
chiller. If the paper-card board is replaced by a perforated plastic tray, the moisture content will have no
effect on the plastic. After removing from the chiller, Dobala packets can be repacked in the papercardboard tray.

Recommended Design of the tray

The tray should be properly perforated so that more surface area of the Dobala is exposed to
atmosphere and the moisture gets evaporated.
On the next page are two recommended designs of the tray.

Recommended Design 1

Figure 1: 3 Dimensional view

Figure 2:Top View

Figure 3: Front view

Figure 4: Side View

Recommended Design 2

Figure 5: 3 Dimensional view

Figure 6: Top view

Figure 7: Side view

Figure 8: Front view

Recommended Dimensions
Dimensions of Recommended Design 1

Detail

Inner Dimensions (mm)

Outer Dimensions (mm)

Length

304.8

306.8

Width

149.86

151.86

Height

121.92

123.92

Base Length

304.8

317.5

Base width

149.86

162.56

Base height

6.475

6.475

Top length

304.8

306.8

Top width

149.86

151.86

Top height

6.475

6.475

Dimensions of Recommended Design 2

Detail

Inner Dimensions (mm)

Outer Dimensions (mm)

Length

304.8

306.8

Width

149.86

151.86

Height

121.92

123.92

Base Length

304.8

317.5

Base width

149.86

162.56

Base height

12.7

12.7

Top length

304.8

311.5

Top width

149.86

156.335

Top height

12.7

12.7

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Recommended Materials for the trays.

Polypropylene (PP)
Polypropylene (PP) is a type of plastic; it has certain properties which suits our requirement.
Following are the properties of PP which make it suitable for the application.
It is
Light
Hard but can be scratched easily
Tough
Good Resistance to Chemicals
Resistant to work fatigue.
Figure 9: Boxes made
up of PP

Toughened Polystyrene (PS)

Polystyrene (PS) is a type of plastic; it has certain properties which suits our requirement.
It has following properties:
Light
Hard
Stiff
Transparent
Brittle
Good wear resistance
Better impact strength than conventional polystyrene

Figure 10: A tray for bottles, made up

of Polystyrene

Polymethyl Methacrylate (PMMA)

PMMA is a type of plastic; it has certain properties which suits our requirement.
Stiff
Hard, but scratches easily
Durable
Brittle in Small sections
Good Electrical insulator
Machines and polishes well

11