Keurig-25 | Multidisciplinary Design Program

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Keurig Dr Pepper (KDP) markets the number one single-serve coffee brewing system in the United States. Students on the Keurig team will design, prototype, and integrate a method to heat and froth dairy and flavorings into an existing brewer and brew engine to deliver a one-step coffeehouse style beverage to home consumers.

Abstract:

Coffee is one of the most popular beverages in the United States. Studies show that an increased number of consumers prefer coffeehouse style beverages to standard drip coffee. In order for Keurig Dr Pepper (KDP) to remain an industry leader, constant innovation occurs to improve the experience of coffee brewing. Keurig is hoping to gain research into inline heating and frothing of dairy and flavorings, and discover ways to incorporate the technology into an existing brewer. Students on the KDP team will be tasked with developing a compact, cost-effective solution that can tune flow rates, temperatures, and beverage textures of dairy, and dispense into the user’s cup from the same location as existing coffee dispensing. Additionally, the team will be tasked with designing around user safety, user experience, cleanability, and design for manufacturability in a high-volume industry.

Impact:

A successful implementation of an inline heating and frothing functionality will help Keurig deliver consumers the coffeehouse style beverages they enjoy in a simple, hands-off approach at home. This development will provide convenience and consumer satisfaction in a growing market, and continue to put Keurig on the top of the home coffee brewing market.

Scope:

Minimum Viable Product Deliverable (Minimum level of success)

Literature review of Keurig best practice design, previous data/project work, and understanding of consumer needs. Include patent search and review of competitors’ product offerings
Development of requirements
Subsystem design and development of inline heater and frother in accordance with sponsor approved manufacturing processes

Expected Final Deliverable (Expected level of success)

Integrate subsystem into existing brewer and brew engine that can
- (1) intake dairy (whole milk from the user)
- (2) heat and froth dairy to a desired specification
- (3) dispense into user’s cup from existing dispense location
Provide a strategy for cleaning any lines or components that contact dairy to meet contamination requirements
Maintain an agreed upon footprint to minimize brewer size
Meet UL safety standards
Validated system against requirements

Stretch Goal Opportunities: (High level of success)

Include multiple settings for dairy temperature and level of froth
Intake dairy alternatives such as lower fat or plant-based options
Integrate inline flavor additive functionality
Incorporate subsystem into existing brewer housing that meets industrial design requirements

Below are the skills needed for this project. Students with the following relevant skills and interest, regardless of major, are encouraged to apply! This is a team based multidisciplinary project. Students on the team are not expected to have experience in all areas, but should be willing to learn and will be asked to perform a breadth of tasks throughout the two semester project.

Mechanical Design (2-3 Students)

Specific Skills: Mechanical Design with specific interest/skill in prototyping, injection molded plastics design, kinematics/dynamics, Solidworks Modeling, and Human factors design

Likely Majors: ME

Thermofluidic Design (1-2 Students)

Specific Skills: Design of fluid path and components to balance flow rates, pressures, and temperatures per specifications

Successful completion of Thermodynamics and Fluid Mechanics or equivalent preferred

Likely Majors: ChE, ME, AERO, NAME

Electronics/Software Design (1-2 Students)

Specific Skills: Electronics design with specific interest/skill in power management and closed loop controls

Likely Majors: EE, ECE, CE, CS

Ingredient Processing (1 Student)

Specific Skills: Knowledge or interest of rheology to determine optimal brewer processes and brew settings to achieve final beverage texture

Knowledge of basic microbiology/food safety standards (or willingness and ability to learn)

Likely Majors: ChE, MSE, CHEM

Additional Desired Skills/Knowledge/Experience

If you have any of these characteristics, highlight them on your Experience and Interest Form and talk about them in your (optional) one way video interview.

Design for manufacturing (specifically in high volume plastic)
Kinematics/dynamics experience
Interest in consumer products
Agile project management experience
Appreciation for coffee is a bonus!

Sponsor Mentor

Charlie DeCataldo

Charlie is a Mechanical Engineer at Keurig Dr Pepper in the Puncture Mechanisms group, working on a variety of improvement and development projects. Prior to joining Keurig, Charlie worked as a Mechanical Design Engineer at Raytheon Technologies, and GE Appliances. Charlie is a proud alumnus of the University of Michigan where he graduated with a B.S.E in Mechanical Engineering. During his time at Michigan, Charlie participated in the Multidisciplinary Design Program on a corporate sponsored team, and worked as a peer advisor for the program.

Nick Borsari

Nick Borsari is a mechanical engineer at Keurig Dr Pepper in the K-Pod Platform Engineering team. He currently works developing thermo-fluid platforms for new brewer systems, while continuously improving existing systems. Prior to joining Keurig Dr Pepper, Nick worked in the defense industry, as a mechanical engineer working a variety of Phase I and Phase II SBIRs. Nick holds B.S. and M.S. degrees in Mechanical Engineering, both from Worcester Polytechnic Institute.

Executive Mentor

Joel Swerchesky

Joel is a Senior Engineering Director at Keurig Dr Pepper leading the system engineering and architectures group. Joel has been with KDP for 12 years, working on product design, quality, and sustaining engineering. Prior to working at KDP, Joel designed vapor compression distillers and large-scale automated assembly machines. Joel has a B.S. in mechanical engineering from the University of New Hampshire and an MBA from Southern New Hampshire University.

Faculty Mentor

Grant Kruger

Dr. Kruger is an Associate Research Scientist in both Mechanical Engineering and the Department of Anesthesiology at the University of Michigan. He is passionate about finding novel engineering solutions to problems faced by care providers and believes in translating these solutions into broader practice. He has a diverse research background, with publications covering areas from Intelligent Manufacturing Systems to Biomedical Engineering. Dr. Kruger’s current research focuses on Biomedical Informatics approaches (robotics, ultrasound, physiologic monitoring, software and firmware development, hardware design, algorithms, signal, image and video processing, and novel prototype manufacturing) based on Computational Intelligence technologies.

Project Meetings: During the winter 2025 semester, the Keurig team will meet on Mondays from 3 – 5 PM. Location TBD.

Work Location: Most of the work will take place on campus in Ann Arbor.

Course Substitutions: CE MDE, ChE Elective, EE MDE, CoE Honors, MECHENG 450, MECHENG 490, SI Elective/Cognate

Citizenship Requirements: This project is open to all students. Note: International students on an F-1 visa will be required to declare part time CPT during Winter 2025 and Fall 2025 terms.

IP/NDA: Students will sign IP/NDA documents that are unique to Keurig Dr Pepper.

Summer Project Activities: No summer activity will take place on the project.

Learn more about the expectations for this type of MDP project