Challenge:
American Surgical Corporation chose Forma to redesign their surgical soap dispenser. The existing market was dominated by a small number of major players. The unit had to be inexpensively configured to dispense either liquid or foam, but foam-generating mechanisms were extremely well protected by existing patents.

Existing bracket designs held the soap bottle from underneath, resting the bottle on a shelf. This shelf tended to collect soap residue and become unsightly. Research in surgical suites revealed that the typical bracket was too wide to enable the desired number of units to be mounted side by side above the scrub sink in an effective way.

Existing dispensers were activated by a foot pump. The presence of multiple dispensers above each sink required multiple foot pumps, which would become rearranged by the simple act of mopping the floor, a common occurrence. Then it would be difficult for surgical staff to find the correct foot pump that would activate the desired dispenser.

Existing dispensers had air intakes located near the floor, an environment high in dirt, bacteria, mold and moisture. The air feed tubes would become contaminated with mold and mildew, an unsightly problem.

Innovative Thinking:

• The dispenser was designed so that it was 30% narrower than competitive products. This enabled the desired number of dispensers to be placed side by side above a scrub sink.

• The bottom of the bottle was angled so that the last drop of soap is dispensed – saving money and decreasing the frequency of bottle replacement.

• Through clever innovation, we avoided any patent infringement on foam-producing mechanisms. The foam produced by our new mechanism exhibits greater uniformity and much smaller bubble sizes; this reduces waste by increasing the retention of foam on the skin during washing.

• The foam-producing mechanism is a stand-alone component that can be introduced into the bottle at the end of the assembly process, allowing flexibility in manufacturing.

• The mounting bracket actually hangs the bottle from the neck, rather than supporting the bottle from the bottom, eliminating any shelf or scum-collecting edges.

• The foot pump design enabled multiple foot pumps to be snapped together, preventing inadvertent rearrangement during mopping.

• The air intake is relocated up off of the floor to reduce or eliminate the mold and mildew problem.

Results:

The design of this surgical soap dispenser represents a significant advance in surgical soap dispensers. Its patented features stack up very well against the competition. Many other features have found their way into competitive products.