Jeremy Calhoun
Product + Systems Designer

Under-Sink Food Waste System

Redesigned a patented product for real-world use, maintenance, and production

product design · systems thinking · manufacturability

Why this Project Mattered

I joined this work with limited professional SolidWorks experience and was tasked with carrying mechanical development forward on a technically demanding product system. The challenge was not just to refine a patented mechanism, but to redesign the full user, service, and production workflow around real cabinet constraints, plumbing variability, moisture-sensitive electronics, and partner requirements.

Version 1 proved the concept. Version 2 needed to prove the product.

What v1 Revealed

The core problem was not composting performance. It was interaction design under physical, environmental, and production constraints.

Version 1 introduced small failures that compounded into daily friction:

The redesign challenge was to reduce friction across the full workflow — install, deposit, empty, rinse, reset — while also simplifying production and assembly.

My Role

After cross-functional definition of requirements and constraints, including partner operational requirements, I led mechanical development execution for v2.

I was responsible for:

Version 1

Constraints

Real-world use

Production and assembly

Partner and compliance requirements

The solution had to satisfy both end-user usability and installation/service operations requirements.

What I Noticed

The redesign was not mainly about improving the mechanism. The friction lived in the moments people actually feel:

That shifted the work from “improve the device” to “improve the full interaction and maintenance system.”

Design Approach

I treated the project as a systems-and-workflow problem rather than a single mechanical object.

  1. Defined the outer size limitations first

    Worked from cabinet and plumbing constraints inward so the architecture would fit real installations, not idealized ones.

  2. Mapped friction points in v1

    Looked across installation, hesitation to purchase/install, mess accumulation, cleaning, maintenance, and recovery after use.

  3. Defined UX success

    Success meant fewer steps, fewer failure points, and faster return to ready state after emptying. That definition had to work for both users and partner operations.

    Deposit → close → empty → rinse/reset

  4. Redesigned the most frequent touchpoints first

    I focused on the actions users repeat most often, then used those interaction goals to drive mechanical and architectural changes.

  5. Used part consolidation to improve both UX and production

    The final objective was not just a better experience, but fewer parts, lower production burden, and less assembly complexity while meeting both our requirements and the partner’s.

Key Design Decisions

Why this Redesign was More than a Form Update

This was not a cosmetic refinement of v1. The redesign changed:

The result was a product that was easier to install, easier to live with, easier to maintain, and simpler to build.

v1 → v2 Comparison

The redesign changed not just the form, but the product architecture, installation method, maintenance flow, and production complexity.

#
Design Aspect
Version 1
Version 2
1
Part Count
130+ components
< 60 components
(consolidated multi-function parts, screw sizes/types)
2
Assembly Architecture
Assembled and accessed from the rear
Core functional unit removable from the front (assembly order + interfaces redesigned)
3
Installation Time
20-30 minutes (w/ no plumbing changes); 6 pages of instructions
< 1 minute (w/ no plumbing changes); 1 page of instructions
4
Installation Method
Standard 3-bolt sink mount; Housing screwed to base of cabinet; Manual Height Adjustment
Custom 3-piece sink mount; Hangs from sink drain
5
Footprint
Larger; limited compatibility in tight spaces
~2" narrower, ~2" shallower, ~1.5"–6.5" shorter height
6
Access & Maintenance
Rear-based access; key parts not removable or repairable
Front opens for fill level check; internal parts removable, cleanable, replaceable
7
Odor Control
Bucket use could expose contents/odours
Maintenance cover closes during bucket removal to limit odour escape
8
Electronics Sealing
Baseline sealing
Improved environmental sealing + internal sealing upgrades
9
Safety
Rubber gasket
Custom sink drain finger guard

Food Waste System v1 → v2

Drag the blue dot to compare size and profile.

v1
v2
Food Waste System version 1
Food Waste System version 2

Outcome

Direct improvements

Downstream effects

Version 2 achieved all internal and partner goals while substantially reducing day-to-day friction.

Reflection

Version 1 proved the mechanism. Version 2 proved that the surrounding workflow mattered just as much as the core technology.

The biggest lesson was that interaction quality under constraint — installation, access, cleaning, and recovery — often determines whether a product feels viable in daily life.

If I were iterating again, I would prototype those friction points even earlier using rough models and real cabinet/plumbing scenarios, then measure: