Product design and development with PCR material

Newell Brands, Chennai, India

October 2023 - February 2024

Product development lead

Led integration of Post-Consumer Recycled (PCR) material into high-volume Kilometric pen production, addressing molding and aesthetic challenges. Initial trials showed short molding due to increased viscosity and inconsistent flow behavior, along with black spot defects caused by foreign particle contamination. Conducted root-cause analysis at the supplier facility and optimized material filtration processes to improve melt cleanliness. Adjusted injection molding parameters, including higher tonnage clamping force and optimized pressure profiles, to ensure complete cavity fill. Validated structural integrity and cosmetic quality through iterative production trials. Successfully enabled sustainable material adoption without compromising part performance or production efficiency.