Case Study: Envirox Chemical Dispensers
Case Introduction:
Our client, Envirox is a local company that had taken over the production of a concentrated cleaning chemical that was used in commercial and industrial janitorial applications. They had a 5-gallon dispenser system made out of vacuum-formed plastic and wanted to move away from this and create a one-gallon unit that was easily portable.
They mixed their concentrated cleaning chemical in large vats and then dispensed these into thick bags which were in a one-gallon square size with a one-time use valve that is pieced with a special tube connection and were in need of a container.
ShapeMaster’s Design Process:
The design requirements of the client were:
- Affordable
- Lightweight
- Durable
The container also needed to have the capability for the customer to add the plumbing inside that flowed the water into a valve that was “selectable” to divert the water and concentrated chemical into different proportions for the different types of cleaning you may be doing. These units also needed to be portable and with metal brackets that would dovetail with a mating bracket to hang on the wall in the janitor’s closet, to provide easy access and fill the desired size container with the chemical mix for various cleaning projects.
After gathering this information from the client, we drew up designs. The design that we created resembled a suitcase with a handle molded in. Once approved, we created a wooden pattern which allowed us to vacuum form a few prototypes for testing. Next, we created the fixtures necessary to trim and assemble the units and then began production once the cast aluminum foundry tool (vacuum forming mold) was ready for use. One of the problems that we had to solve in this process was how to drill and route the many odd-shaped holes for plumbing fittings into the case. We were able to accomplish this by drilling holes using 12” long bits with hole saws customized for the process. The two halves of the container were then glued together forming a nicely designed system.
Solution:
In the end, we were able to provide the client with a convenient solution to mix their chemical product. We made these units for many years and delivered 80 complete dispensers to their chemical plant in Danville, IL weekly.