Design Life-Cycle

Materials Paper 

Katie Phan

Group Members: Cindy Zhu, Anqi Su

DES 40A / SQ 24

Professor Cogdell / Section 5

June 4, 2024

Bodum Chambord French Press: Raw Materials

Amongst many coffee enthusiasts, the French press is widely known for its simplicity and brewing abilities. The Bodum Chambord French Press has been a staple in coffee culture and has been around for decades. The Bodum Chambord French Press features a glass carafe encased in a stainless-steel frame and lid that has been chrome plated. Its handle is composed of polypropylene, which allows for a more comfortable grip. Additionally, its plunger is made of stainless steel and is equipped with a fine mesh filter. The Bodum Chambord prides itself on being an environmentally friendly coffee-brewing method due to its lack of use of paper filters or plastic capsules. The lifecycle analysis of the raw materials used in this product explores the multifaceted environmental benefits of the Bodum Chambord French Press, highlighting its eco-friendly raw material extraction, production processes, transportation methods, maintenance practices, recyclability, and waste management strategies while also underscoring its significant contribution to sustainable coffee culture.

The Bodum Chambord French Press is a product of careful selection and acquisition of high-quality raw materials. The primary materials used in its construction are borosilicate glass, stainless steel, and polypropylene plastic. The carafe of the French press is made from heat-resistant borosilicate glass. This glass is produced using boric oxide, silica sand, soda ash, and alumina and is known for its durability and resistance to thermal shock. The frame and most of the lid are made of stainless steel, a robust and corrosion-resistant material. The handle, plunger, and lid screen are made of polypropylene plastic, a versatile and safe material since all these plastic parts are BPA free. The sourcing of these materials is a critical aspect of the manufacturing process. However, the specific details about how Bodum sources these materials are not readily available, limiting the scope of the raw materials acquisition process. The combination of these materials results in a product that is not only functional and durable but also aesthetically pleasing.

The Bodum Chambord French Press is manufactured using three main materials: borosilicate glass, stainless steel, and polypropylene plastic. Borosilicate glass is produced by combining and melting boric oxide, silica sand, soda ash, and alumina. This glass is then used to form the main part of the French press, the carafe. Additionally, the stainless steel is created in an electric furnace by melting iron ore, chromium, silicon, nickel, and other elements for 8 to 12 hours in intense heat. The molten mixture is then cast into various shapes, such as blooms, billets, and slabs, that will then be used to form various parts of the French press. This stainless steel is chrome plated to make the frame that encases the carafe  and to make the lid of the French press. It is also used to make the plunger and the fine mesh filter that is used to press and strain the coffee. The plunger is topped by polypropylene plastic, which is made by transforming propylene gas through a process called polymerization, using a catalyst system. The specifications for this, such as temperature, pressure, and reactant concentrations, are carefully controlled to produce the specific polymer grade. This plastic is also used to form the handle, allowing for a comfortable way to hold the French press. After all of these elements are combined, the French press is then wrapped in a thin, soft plastic sleeve and placed into a cardboard box, allowing it to be ready for shipping.

Bodum, the manufacturer of the Chambord French Press, operates facilities in several countries worldwide, including Portugal, Germany, Poland, France, and China. This global presence necessitates a complex and efficient transportation process to distribute their products. While specific details about the vehicles and fuel types used are not easily accessible, it can be inferred that the transportation process likely involves a combination of shipping and trucking services. Cargo boats, which typically use bunker fuel, are likely employed for long-distance, international transportation. Bunker fuel is made as a result of distilling and cracking petroleum. These boats can carry large quantities of products, making them an efficient choice for transporting goods across continents. On the other hand, trucks, which generally use diesel fuel, are probably used for shorter, overland routes, such as delivering products from ports to retail locations or distribution centers. Diesel fuel is created through the refining of crude oil and biomass. This multi-modal transportation strategy allows Bodum to effectively deliver their products to customers all around the world.

The Bodum Chambord French Press is a user-friendly and efficient coffee maker. To use it, simply add coarsely ground coffee to the beaker followed by hot water. After waiting for 4 minutes to allow the coffee to steep, slowly press down the plunger to separate the coffee grounds from the liquid. This process ensures a rich and flavorful cup of coffee. When it comes to maintenance, the Bodum Chambord French Press is designed for easy cleaning. The glass beaker and stainless steel filter are dishwasher safe, making them convenient to clean after use. The exterior housing, on the other hand, can be kept clean by wiping it with a damp cloth. This combination of ease of use and straightforward maintenance makes the Bodum Chambord French Press a popular choice for coffee lovers.

The recycling process for the materials used in the Bodum Chambord French Press, namely glass, stainless steel, and plastic, is a multi-step procedure. For glass, it includes collection, transportation, sorting, breaking, screening, drying, pulverizing, and classifying the waste. Once glass is crushed and collected, it’s sorted based on color and composition, enabling it to be melted based on its chemical composition. The crushed glass is then cleaned to remove any impurities, allowing it to be reused again to form new glass. The stainless steel undergoes collection, sorting, purification, size reduction, and remelting. The recycling process of polypropylene, a type of plastic, involves several key steps. Initially, the plastic waste is collected and transported to a Material Recovery Facility. The collected waste is then sorted based on the type of plastic, often identified by a printed ‘resin code’. Following this, the sorted plastic is cleaned to remove any impurities. The next step is reprocessing, which involves shredding the plastic into small pieces and melting it. The melted plastic is then molded into new products such as plastic pallets, garden furniture, and storage bins. Additionally, research by Vineta Srebrenkoska has found that recycling processes for polypropylene-based composites, especially those reinforced with kenaf fibers, lead to small changes in their bending strength and heat resistance. These composites exhibit less sensitivity to reprocessing cycles compared to those strengthened with rice hulls. This resilience is hopeful, as their quality largely remains the same even after recycling and reprocessing. Furthermore, the recycled composites can be reused in other implementations, such as construction materials and indoor uses. Moreover, the cardboard box that the Bodum Chambord French Press comes in is also recyclable. After the cardboard box has been collected, it is sorted into specialized recycling processes. It is then shredded and pulped, so that the pulp can be filtered to remove contaminants. The pulp is then dried and finished to form new sheets of paper again. The recycled material is then used to make corrugated cardboard or sold to other companies that convert the paper into other materials. Cardboard boxes are able to be recycled around 20 times before the fibers become too weak to be reused, emphasizing how Bodum’s packaging is a great choice in terms of reusability and eco-friendliness. This recyclability of their materials makes the Bodum Chambord French Press not only a great tool for brewing coffee but also a product that considers the environment in its manufacturing and recycling processes.

Because the Bodum Chambord French Press is made out of glass, stainless steel, and plastic, it is a product that is easily recyclable. This leads to little to no waste occurring at the end of its life cycle. Furthermore, the grounds used when brewing coffee in the French press are fully compostable, allowing no waste to be produced. Additionally, the fine mesh filter that is built into the French press leads to the lack of a need for paper filters. This further reduces the amount of waste created when brewing coffee in the Bodum Chambord. Moreover, the packaging that the Bodum Chambord French Press is sold in can also be easily recyclable because it is made out of cardboard. This greatens Bodum’s eco-friendliness due to both their product and packaging’s recyclability. Therefore, the amount of waste the Bodum Chambord French Press produces throughout its lifecycle process is little to none. However, there is potential for some waste to be produced. This potential lies with the polypropylene plastic, especially those that have not been reinforced with kenaf fibers, due to its degradation each time it is recycled. Because of this, the plastic eventually becomes waste in the landfill where it will take 20-30 years for them to break down into microplastics. Additionally, the recyclability of polypropylene is also limited because approximately 1% of users actually recycle the material. This causes the plastic to be taken to the landfill where, unless it is sorted to be recycled, it becomes waste.

The lifecycle process of the Bodum Chambord French Press exemplifies a sustainable approach to product design and waste management. From its initial use to its eventual disposal, each stage has been thoughtfully designed to minimize environmental impact. The French press is made from recyclable materials such as borosilicate glass and stainless steel, which can be repurposed through recycling processes that maintain their inherent properties. Even the coffee grounds used in the brewing process are fully compostable, further reducing waste. When the product reaches the end of its lifecycle, the materials are separated and undergo specific recycling processes, ensuring they do not go to waste and can be reused to produce new products. This comprehensive approach to the product’s lifecycle not only contributes to environmental conservation but also sets a benchmark for sustainable product design.

Work Cited

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Embodied Energy Paper

(Will Be Posted On Later Date)

Waste and Pollution Paper

Anqi Su

Group members: Cindy Zhu, Katie Phan

Professor Christina Cogdell

Energy, Materials, & Design Across Time (Section 5)

4 June 2024

Waste: Bodum Chambord French Press Recyclability and Sustainability

The pride and joy of Bodum Chambord is its iconic Chambord French press, synonymous with its name.  The original design dates back to the pre-war period when Italian Attilo Calimani developed the basic principle of this French press. Bodum’s founder, Jorgen Bodum, began to work on his version of the French press in the 1970s, but it was the 1991 acquisition of Melior-Marten — a company that produced a dome-shaped French press — that led to the development of the classic Chambord that is so popular today.  Bodum’s motto is ‘make taste, not waste,’ which highlights Bodum’s core value of creating environmentally friendly methods of brewing through high quality products. 

One of the Chambord French press’s main features and benefits is that the carafe is made of stain-resistant, heat-resistant borosilicate glass that will not alter or impair the coffee’s natural flavor.  Bodum promises that their French press coffee maker brings out the full flavor and aroma of each brew.  The frame and lid is made from a durable stainless steel that has undergone several chrome-plating processes to result in a durable, shiny surface that is capable of withstanding many years of regular use.  Additionally, the handle is also made from PP plastic (polypropylene) with a matte finish that gives the user a comfortable grip.  A stainless steel plunger also prevents ground beans from escaping when the coffee is poured.  Although borosilicate glass is known to be extremely difficult to recycle and most plastics usually do not end up getting recycled,  the Chambord French press coffee maker is still a very sustainable method of brewing coffee because of its high quality, long-lasting design and recyclability of its other materials.  In other words, very little waste comes from the life cycle of the product.

The French press’s frame, lid, and plunger are made from stainless steel, which is not only durable, but also fully recyclable without any quality degradation; stainless steel can be recycled infinitely without any signs of quality degradation during reprocessing.  Because of how viable recycling stainless steel is, the end-of-life recycling rate for stainless steel is over 80% on average, meaning there is very little waste that comes from incorporating stainless steel into the design as stainless steel parts have a high chance of being recycled instead of landing up in landfills and the environment.   The primary alloy elements of stainless steel, which include nickel, chromium, and molybdenum are all extremely valuable and can be recovered easily when the stainless steel is being recycled, further incentivising high recycling rates.  To add on, according to the British Stainless Steel Association, any stainless steel object has an approximate recycled content of 60%.  This is evidence of stainless steel being repurposed, instead of becoming waste.  The importance in recycling is not only to reduce waste and pollution, but also to conserve non-renewable resources and to save energy.  Besides its high recyclability, stainless steel products have a long life as they are durable and do not corrode, so it is not often that they can potentially end up as waste.  The only waste products that come from the recycling process are mostly the greenhouse gasses that are produced by recycling machinery, but the total amount of emissions that are released from recycling stainless steel and  synthesizing stainless steel from recycled stainless steel is much less than creating stainless steel from raw materials.

However, unlike stainless steel, one can make the argument that PP plastic is not a sustainable aspect of the French press’s design as the likelihood of plastics getting recycled is slim.  PP plastic is a type of thermoplastic that is a petrochemical-based material that, when malleable, can be molded into varying shapes.  The extraction and processing of the fossil fuels required to produce plastic contribute to the destruction of habitats, contamination of water bodies, and emission of greenhouse gasses.  The fossil fuels undergo energy-intensive processes to be refined into polymers during the production phase, and greenhouse gasses and other contaminants are emitted.  PP plastic is easy to recycle, but a lot of it usually ends up in the landfills or in the sea through waterways formed by lakes, rivers, and streams.  Even if plastics are recycled, significant emissions may be produced during the transportation of the plastic and much energy is needed for the recycling process.  Also, because reprocessing plastics cause its quality to degrade, the recycling process often involves mixing in freshly made plastic or toxic additives to restore desirable properties, which is toxic for the environment and can make future recycling tricky.  Recycling plastic is extremely important because if the plastic ends up in water bodies, the degradation of the plastic generates microplastics and nanoplastics can be readily consumed by marine animals.  Microplastics and nanoplastics obstruct the digestive tract (thereby resulting in pseudo-satiation and a reduction in food absorption) and have the potential to transport chemical contaminants and heavy metals into the bodies of such marine animals.  Plastic degradation also has negative effects on soil fertility and has potential to disturb ecosystem services, leading to adverse effects on water quality, ecosystems, and economic sectors such as fisheries and tourism.  Because of its resistance to breaking down, once a piece of plastic ends up in the wild, it can stay there for a very long time without human intervention.  Recycling can lead to reduced emissions (producing something using recycled materials requires less energy than producing something from raw materials), minimize natural resource depletion, decrease value loss, and is effective for continuing a circular economy.

On the contrary, the Chambord French press is made to last.  The decision to incorporate PP plastic into the design is due to the fact that PP plastic is tough, rigid, and hard.  The plastic is BPA free, non-deformable, and has a low water absorptive capacity and vapor permeability, which make the product dishwasher safe and able to hold a hot beverage such as coffee safely.  If the French press is supposed to be reusable, then it has to be made with resilient materials that allow it to be used over and over again for a long, long time.  Otherwise, the design would contradict with the product’s intended reusability power.  Even though the PP plastic used in the design is not the most environmentally friendly option at the end of its life cycle, needing to replace the French press with a new one just because it cannot be used for a long time would be more wasteful than using the same French press for a much longer time, even if some of its proponents are not incredibly environmentally friendly at the end of its life cycle.  Bodum Chambord boasts the fact that one-time use of plastic coffee pods and paper filters are not necessary when brewing coffee with their French press so if the French press itself is not reusable for long, its purpose would be defeated.

Like PP plastic, borosilicate glass is not very recycle-friendly.  For particularly durable glass like borosilicate glass, the proportion of lime and sodium oxide is reduced to a total of 4-8% and 14% boron trioxide and 2-7% aluminum oxide are added instead.  The addition of these substances makes the glass particularly resistant to chemical effects and high temperature fluctuations.  Recycling borosilicate glass is difficult because of its much higher degree of melting compared to soda lime glass – borosilicate can maintain its strength and transparency even when exposed to a working temperature of 515 degrees Fahrenheit and only melts at 3,000 degrees Fahrenheit.  Recycling borosilicate is not impossible, but the facilities that have the capacity to recycle the glass are extremely rare.  Additionally, not enough of this type of glass gets disposed of, which makes collecting, shipping, and processing the glass a costly process.  Only a small percentage of overall borosilicate glass are used by consumers, so it has yet to become viable to recycle at a large scale.

In opposition to the reasons for why borosilicate glass is not the most eco-friendly option, the strong nature of the glass allows the borosilicate carafe of the French press to be able to withstand the temperatures of hot coffee and to be used on a regular basis for a long time.  This means that borosilicate glass, although not always recyclable, is significantly more sustainable than single-use or few-time-use solutions.  In situations where borosilicate can be recycled, it can go through the recycling process any number of times without losing raw mass.  Recycling borosilicate conserves the resource sand, which is becoming increasingly valuable due to its heavy use in construction.  

Even though not all of the materials of the Bodum Chambord French press coffee maker are not incredibly sustainable options, the unwavering durability of the PP plastic and borosilicate glass compensate for their difficulty of being recycled.  The French press can last a lifetime when handled properly.  To reuse the French press, it just simply has to be washed in warm, soapy water and then dried.  In this sense, reusing a French press made of durable materials for a long time is far more sustainable than using plastic coffee pods and paper filters that have a great chance of ending up in a landfill or the ocean rather than be recycled.  Even though borosilicate glass and PP plastic also have unlikely chances of being recycled, the number of times that these materials would have to take that gamble is a lot less than that of coffee pods, filter papers, or of plastic or glass of lower durability but easier recyclability.

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