THE FUTURE OF AIRPLANE DINING
Experience convenient, efficient and sustainable dining in the air
VISION
"We are changing the way catering is perceived."
Our goal for this project was to design something that helps catering storage more efficient in aviation. In the current situation, the meals are stored on trays stacked in trolleys. In our field research, we saw there was much space between these trays that was going to waste. If we could design something that ensures a more efficient way of storing the meals, possibly less trolleys have to be necessary for the flight. This would ensure a major weight saving, and therefore fuel saving. Also, the decrease in space taken up by trolleys could in the future be occupied by extra seats, causing the flight prices and amount of flights to drop.
Less flights mean less harmful exhaust fumes to be created, and this would be beneficial against air pollution.
THE PRODUCT
Effortlessly unfolds
for easy access.
HOW DOES IT WORK?
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We as a team ... Introducing HexaDine: the ultimate solution for luxury in-flight dining aboard KLM flights. Our innovative product is a hexagonal packaging that unfolds to reveal a beautifully presented meal. It replaces traditional trays and offers optimal space saving, requiring fewer trolleys and reducing weight onboard. This efficiency not only reduces operational burden but also enhances flight sustainability. HexaDine: where convenience, efficiency, and sustainability converge.
Hot
Cold
Cutlery
PROCESS ON BOARD
Catering service puts it in the oven
Meal gets warmed up
Cabin crew takes it out of the oven and puts it into the HexaDine
Cabin crew serves the meal to passengers
PROTOTYPE
The concept has been prototyped using a 3D-printer. This prototype is being used as a way to experience the HexaDine as a tangible product, instead of a digital visualization. This 3D-print could be used to test the product in a simulated environment, in order to reach technology readiness level 3. The material it is made from is PET, this is a different material than the material that the end product will be made of (ABS). Therefore, this prototype can solely be used to test the performances of the shape, and usability. Another prototype will have to be made from ABS to test the material performance.
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CATERING SYSTEM
SUSTAINABLE THROUGHOUT THE WHOLE SYSTEM
Our product is a sustainability champion at every step of the journey. By opting to retain the existing trolleys, we minimize waste and maintain compatibility with the current infrastructure, including catering, aircraft, and cleaning protocols. Additionally, our design prioritizes easy cleaning, ensuring reusability and further reducing environmental impact.
SUSTAINABILITY IMPACT
Now, a trolley measuring 0.5 by 0.75 by 0.3 meters carries 24 meals on trays (Meal Trolley — Air Travel Design Guide, z.d.). If instead of trays, the spatially efficient hexagon-shaped boxes are used, 40 meals can be carried per trolley. This is 16 meals more per trolley. When we use this more efficient way of loading meals fewer trolleys are needed per flight. if we assume there are 150 people on a plane, around 7 trolleys are needed (including meals for crew and margin etc.). When we use the more efficient hexagon box only 4 trolleys are needed. A trolley weighs 25 Kg. This means that when airlines use the hexagon boxes they can reduce 75 Kg from the total weight of the plane.
With the use of several sources, we were able to calculate the amount of money, kerosene (Belgium Kerosene Prices, 15-Apr-2024 | GlobalPetrolPrices.com, z.d.), and CO2 emission (Editor Engineeringtoolbox, 2024) that would be saved by reducing the weight of a single airplane. we can also calculate how much CO2 trees absorb (EcoTree, z.d.). So 2,52 trees absorb the same amount of CO2 in a year as is saved by the weight reduction of 75 Kg per flight.
Fits 12 trays
Fits 20 HexaDines
MATERIALS
The material chosen for the hexagon tray is ABS (Acrylonitrile Butadiene Styrene). This material was selected because it is sturdy and hard, easy to work with, relatively lightweight, and has good surface finishing. Additionally, it is heat resistant.
The ABS tray will be treated with a nanocoating. These coatings consist of nanoparticles suspended in a liquid solution. These particles are so small that they operate on a nanoscale (one billionth of a meter). When the liquid is applied to the surface, the nanoparticles adhere to the substrate, forming a thin, even layer. This enhances the product's properties, such as scratch resistance, water repellence, dirt repellence, and self-cleaning properties. This is important not only to ensure that the tray looks hygienic but also that it actually is.
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The hinges that are used for opening the hexagon tray, will be made from stainless steel. This material was chosen because of durability reasons and corrosion-resistance.
COLLABORATION KLM
Our collaboration with KLM embodies their values: passion, innovation, responsibility, and care. Our product design reflects these values, delivering excellence, sustainability, and passenger comfort. Together, we've crafted a solution that redefines in-flight dining, aligning with KLM's commitment to excellence and customer satisfaction.
RESEARCH
To gain insight into how catering works within KLM, we researched how the entire system works and how the catering service on the aircraft works. To do this, we conducted several interviews with stakeholders and desk research.
First, with a sustainability manager at an airline catering company. The biggest conclusion from this was that there can be a lot done on weight reduction. And
We also interviewed a KLM flight attendant several times. During one of the interviews, we learned that KLM is already working hard to become more sustainable. KLM is focusing on five areas: weight reduction, engaged suppliers, smart packaging, responsible ingredients and waste management. (Onboard Sustainability, KLM)
There are already many smart sustainable solutions, but we wanted something that has not been done before. In addition, the interviews showed that there is a lot to be gained in this area. So we chose to design something for weight reduction. We looked back at the first five weeks, where a recurring problem was the lack of space. We found this to be an interesting problem.
FUTURE
Technology readiness levels (TRL) are levels that range from level 1 to level 9, with level 1 being conceptualization and level 9 full implementation of the product. It helps in evaluating the readiness of a technology for implementation or integration into a larger system.
Currently, the concept of HexaDine is at level 2. We now have the concept concretely formulated, and a prototype has been made. This 3D-printed prototype can now be tested in a simulated environment, in order to reach level 3. The goal for the future is to continue the development and to complete all the levels in order to implement the concept in aviation. (Technology Readiness Levels (TRL), n.d.)
STAKEHOLDERS
In the airplane catering system, there is a stakeholder to whom this process must work efficiently. In this system map a sticky note represents the stakeholders. The blue sticky notes are stakeholders that are part of the KLM company. The green sticky notes resemble airports. The Other color's sticky notes are stakeholders that are remaining.
The arrows between stakeholders show what the stakeholder's relationship with each other is. A green arrow means yet-to-be-consumed food. A brown arrow means leftover food and package material. A yellow arrow resembles money streams. A blue arrow resembles employment. The remaining arrows are black.
From this stakeholder system map, we can conclude the cabin crew and the catering company are most central. That is why we mostly focus on those stakeholders in this project. (Kitch, 2023)
USER
For the typical economy class traveler, comfort, affordability, and efficiency are paramount. While they may not expect exclusive luxury, they appreciate good service from the crew. Our product is designed with their needs in mind, offering enhanced comfort and convenience without compromising on affordability. By prioritizing efficiency, we ensure a seamless travel experience, allowing passengers to relax and enjoy their journey with peace of mind. (Van Boeijen et al., 2020)
OUR PROCESS
Our design journey was a systematic exploration, beginning with challenging risky assumptions through interviews and desk research. Field research and stakeholder mapping deepened our understanding, while market research provided valuable context. In the concepting phase, we employed the "how to" method, visualizing ideas through sketching, modeling, and crafting 3D prototypes. Finally, rigorous prototype and requirement testing ensured our solutions met user needs and surpassed expectations.
RESOURCE LIST
A frontrunners journey. (z.d.). KLM.
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Antoine. (2023, 29 september). How can airlines cut weight to boost flight efficiency. OpenAirlines.
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Belgium kerosene prices, 08-Apr-2024 | GlobalPetrolPrices.com. (z.d.). GlobalPetrolPrices.com. https://www.globalpetrolprices.com/Belgium/kerosene_prices/
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Duurzaamheid. (z.d.). Klm. https://www.klm.nl/information/sustainability
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E-Book Onboard Sustainability. (z.d.). KLM.
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EcoTree. (z.d.). How much CO2 does a tree absorb? Let’s get carbon curious! EcoTree. https://ecotree.green/en/how-much-co2-does-a-tree-absorb#:~:text=A%20tree%20absorbs%20approximately%2025kg%20of%20CO2%20per%20year&text=But%20really%20a%20tree%20absorbs,a%20tree%20absorbs%20so%20interesting
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Editor Engineeringtoolbox. (2024, 8 april). Combustion of Fuels - Carbon Dioxide Emission. https://www.engineeringtoolbox.com/co2-emission-fuels-d_1085.html
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Morris, H. (2018, 3 september). Airline weight reduction to save fuel: The crazy ways airlines save weight on planes. The Sydney Morning Herald. https://www.smh.com.au/traveller/reviews-and-advice/airline-weight-reduction-to-save-fuel-the-crazy-ways-airlines-save-weight-on-planes-20180903-h14vlh.htmlof
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Virgin Atlantic. (2023). Virgin Atlantic History. In Press Kit. https://corporate.virginatlantic.com/content/dam/corporate/media-centre/Press%20Kit%202023.pdf
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Why choose KLM. (z.d.). Klm. https://www.klm.nl/en/information/corporate/benefits-klm
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Van Boeijen, A., Daalhuizen, J., & Zijlstra, J. (2020). Delft Design Guide : Perspectives -
Models - Approaches - Methods.
Technology Readiness Levels (TRL). (z.d.). RVO.nl. https://www.rvo.nl/onderwerpen/trl
Kitch, B. (2023, 20 november). How to create a stakeholder map [templates & examples]. Mural. https://www.mural.co/blog/stakeholder-mapping