1

MR. COFFEE – REDESIGN AND CONCLUSIONS

Industrial Ecology – Spring 2012

2Recap Redesign Conclusions

Table of Contents

Recap – Disassembly & Analysis ConclusionsRedesign – Use Phase and Additional ImprovementsConclusions – Total Impact Reduction

3Recap Redesign Conclusions

Disassembly- Explosion Diagram

http://www.buyspares.co.uk/tefal/coffee-makers/896115-vitesse-coffee-maker/catalogue.pl?shop=tefal&path=290047&model_ref=41271&illustration_ref=27443

4Recap Redesign Conclusions

Eco Audit- Energy SummaryPhase Energy (MJ) Energy (%) CO2 (kg) CO2 (%)Material 139 4.7 6.43 3.7Manufacture 30.4 1.0 2.31 1.3Transport 3.87 0.1 0.275 0.2Use 2.77e+03 94.1 167 94.8Disposal 1.3 0.0 0.0912 0.1Total (for first life) 2.94e+03 100 176 100End of life potential -33.3 0.968

Carbon and Energy Totals

5Recap Redesign Conclusions

Eco Audit- Water Consumption Summary

USE(99.5%)

Materials, Manufacturing, End of Life(.5%)

6Recap Redesign Conclusions

Problem Statement – Where we left off

Identify

• 14 Million Coffee Makers are sold each year in the United States(consumer watch)

• Consumer coffee makers require energy to compensate for heat loss.

Hypothesize

• Reduce Energy Consumption during use through redesign• Aim to move to insular materials to reduce waste heat• Reduce energy consumption through behavioral change

Impleme

nt

• Energy conservation by changing key components: Pot, Conductive plate and Heating element

• Propose Use Based conservation– How many cups do you drink compared to your waste?

Recap Redesign Conclusions

Function, Objectives, Constraints, Free Variables

• Provide at home fast, easy, cost efficient coffee

Function

• Produce hot water at appropriate temperature for coffee brewing

Objective

• Water Resistance, heat resistance, stiffness, capacity

Constraints

• Heating time, material choice, material thickness

Free Variables

Recap Redesign Conclusions

Redesign – Design RequirementsComponent Function Objective Constraints Free Variables

Packaging Protection/Marketing Minimize Eco- Impact Load < Damaging Load

Material Choice, Thickness

Polypropylene Shell Structure & Support Minimize Eco- Impact and maintain cost

Stiff and Strong Enough, Cost

Material Choice, Thickness

Electronics Controls machine operation

Minimize Eco- Impact Simple Coffee Controls

N/A

Filter Basket Hold Coffee Grinds Minimize Eco- Impact Stiff and Strong Enough, Cost

Material Choice, Thickness

Coffee Pot Contain and Insulate Coffee

Reduce Thermal Losses

Contain 8 Cups, Hold Liquid

Material Choice, Thickness

Heating Element & Tubing

Heat the water Reduce Thermal Losses

Electric – Thermal Conversion

Material Choice, Thickness

Recap Redesign Conclusions

Redesign – Coffee Pot Materials Selection

Recap Redesign Conclusions

Redesign – Analysis of Polypropylene

Recap Redesign Conclusions

Redesign – Analysis of Polypropylene

Recap Redesign Conclusions

Use Phase – Key Design Changes

• Insulated Coffee Carafe• Heating Element Location• Stainless Steel Reusable Filter• 8-cup Water Capacity

Recap Redesign Conclusions

Redesign: Insulating Carafe

• Dual shell vacuum insulation.

• Minimal points of contact.

• Minimal heat loss by conduction.

• Keeps coffee warm at 160F (71C) for up to 6 hours.

• No need for reheating of coffee

Recap Redesign Conclusions

Redesign: Result of Insulating Carafe

• Heat transfer by conduction. • Heat transfer is minimized by the

coefficient of thermal conductivity of insular material.

• Heat transfer is minimized by the insulation thickness.

Energy Calculations. - Input at 900watts -10min/day on time

Energy = 900J/s*600s=540kJ/day - Life time = 6yrs Energy = 540kJ/day*365day*6years=1182.6MJ/lifetime

Life time energy saving2770MJ-1182.6MJ=1587MJ57% cut in energy consumption

Recap Redesign Conclusions

Usage Adjustments – Reusable Filters

Saves up to 334.3 MJ of energy and 7.5kg of CO2

Energy (MJ)

CO2 (kg)

Stainless Steel Reusable Filter

Total Before End of Life 7.7 0.5

Total After End of Life 2.0 0.2

Paper Filters Total 336.3 7.7

Recap Redesign Conclusions

Usage Adjustments – Reduction in Water Capacity

Original Use Water Consumption: 93,220kg

• By reducing capacity to 8 cups, an estimated

reduction in daily use is 2 cups

Total Use = 74,661kg

New Water Consumption:

Water Savings: 18,559kg

Recap Redesign Conclusions

Redesign – Analysis & Redesign of Packaging Materials

Original PLA0

2

4

6

8

10

12

14

Energy (MJ) in Packaging Materials

    Material   Manufacturing Total (MJ)

OriginalPlastic Bag 1.7MJ 0.13

0.66MJMJ

  Styrofoam 10MJ

Original Total 11.7MJ 0.79MJ 12.49New PLA 1.546MJ 0.18MJ 1.726

Energy Savings   10.76

Recap Redesign Conclusions

Redesign – Eliminating water transport in Use phase

Assumptions:• The entire reservoir,8 cups is transported through the

machine in approximately 10 minutes• The Coffee is warmed to 90.5-96C (Environmental

impacts of different methods of coffee preparation by Eva Brommer,Britta Stratmann and Dietlinde Quack)

• Energy losses can be directly correlated to energy savings.

• Room temperature is 23 degrees Celsius.• The tubing is a perfect cylinder of length .3556

meters• Coefficient of Thermal Conductivity of the Tubing

is .13 W/mK (http://www.engineeringtoolbox.com/thermal-conductivity-d_429.html)

Recap Redesign Conclusions

Redesign – Calculating Energy Gains

Recap Redesign Conclusions

Redesign – Calculating Energy GainsTemperature© Q (W/m) Energy Lost Per Year Per Life Cycle

90.5 -40.248731 -8587.469264 -3.1344263 -18.80655769

91 -40.384441 -8616.424283 -3.1449949 -18.86996918

91.5 -40.519953 -8645.337254 -3.1555481 -18.93328859

92 -40.65527 -8674.208508 -3.1660861 -18.99651663

92.5 -40.790394 -8703.038368 -3.176609 -19.05965403

93 -40.925324 -8731.827154 -3.1871169 -19.12270147

93.5 -41.060064 -8760.575181 -3.1976099 -19.18565965

94 -41.194614 -8789.282762 -3.2080882 -19.24852925

94.5 -41.328975 -8817.950204 -3.2185518 -19.31131095

95 -41.463151 -8846.57781 -3.2290009 -19.3740054

95.5 -41.59714 -8875.16588 -3.2394355 -19.43661328

96 -41.730946 -8903.714709 -3.2498559 -19.49913521

Energy Consump-

tion Source

Disposal Phase Eliminating Water

Transport

Transportation Phase

Manufacturing Phase

0

5

10

15

20

25

30

35

Saves Approximately 18 MJ Per Unit

Recap Redesign Conclusions

Redesign:

Recap Redesign Conclusions

Redesign: Water & Heating Diagram

Recap Redesign Conclusions

Redesign: Filter & Basket

Recap Redesign Conclusions

Redesign: Cumulative Results

Improvement CO2 Reduction (kg)

Energy Reduction

(MJ)

Water Consumption

(kg)Insulated Pot 85 1587 N/A

Packaging Materials

.35 10.76 12

Reduction of Water Capacity

N/A N/A 18559

Relocation of Heating Element

N/A 18 N/A

Recap Redesign Conclusions

Conclusions- Overall Impact

Water Reduction (kg) CO2 Reduction (kg) Energy Reduction (MJ)0%

20%

40%

60%

80%

100%

120%

21%53% 66%

Summary of Reductions Through Redesign

Recap Redesign Conclusions

Conclusion

Comparability:• Costs – New Design is in the same price bracket as original• End-of-Life – Both glass and stainless steel can be recycled

Significant Findings:• Insulated carafe is responsible for the most dramatic

energy savings• Stainless steel would be an easy substitute for the glass

carafe

Recap Redesign Conclusions

Final Conclusions and Changes

1.Insulated Carafe

2.Reusable Stainless Steel Filter

3. 8-Cup Water Capacity

4.Location of the Heating Element

Recap Redesign Conclusions

Works Cited

http://www.buyspares.co.uk/tefal/coffee-makers/896115-vitesse-coffee-maker/catalogue.pl?

shop=tefal&path=290047&model_ref=41271&illustration_ref=27443

http://www.statista.com/statistics/220433/life-expectancy-of-coffee-machines/

http://www.energystar.gov/ia/products/downloads/ENERGY_STAR_Scoping_Report_Coffee_Makers.pdf