Design Life-Cycle

Kai Luna

Professor Cogdell

DES40A Winter 2023

14 March 2023

Monster High Doll Life Cycle - Raw Materials

The Monster High doll is one of the many products found on the shelves of superstores and online. However, the materials used to make this popular doll and their impacts on the environment are often overlooked. The raw materials acquisition to make the synthetic materials, the plastic for the body; vinyl for the head; and the synthetic fabric for the clothes, that the Monster High doll is made of have such a harmful impact on the environment. Mattel has a recycling program for their toys in progress, however when recycling plastic, more plastic must be made to be added to the recycled plastics.

It is assumed that the materials used to construct the Monster High doll are all synthetic. Since Barbie is produced by the same manufacturer, Mattel, as the Monster High doll, then the materials for the body should be the same. The head of the doll is made of vinyl. The arms are made from EVA plastic, the torso from ABS plastic and the legs are made from PVC plastic (“Life in Plastic: How Mattel Created Its New, Diverse Line of Barbie Dolls”). Same as Barbie, the hair of the doll is made from saran fibers, as well as tinsel in some dolls (Emily). 

The vinyl used for the head of the doll is made up of ethylene found in crude oil, and chlorine from salt (“What Is Vinyl? Vinyl Material Properties, Discovery & Applications”). The EVA plastic used for the arms is defined as a copolymer of ethylene and vinyl acetate (“EVA Material Properties”). The ABS plastic used for the torso is made up of three monomers called Acrylonitrile, produced of propylene and ammonia; Butadiene, made from ethylene; and Styrene, made from ethylene and benzene. Both propylene and ethylene are derived from petroleum, and the benzene is from crude oil. The PVC for the legs are a product of additives combined with vinyl chloride monomer (VCM). The VCM is made up of chlorine, from salt water, and ethylene, from oil ( “Polyvinyl Chloride PVC”). The additives for the PVC are stabilizers and lubricants, as well as fillers and pigments ( “PVC Additives - PVC”). The saran fibers for the hair are made of polyvinylidene chloride ( “Saran Fiber”), and the tinsel comes from PVC’s (Harvey). In summary, the vinyl, ABS plastic, PVC plastic, and tinsel are derived from oil, then EVA and ABS are from petroleum. 

The Monster High doll is widely known for their fashion aspect, with each new release coming with a different outfit design. Mattel has a history of making clothing for their dolls, with Barbie, so it can be assumed that they use the same material for the Monster High dolls. The materials used for the doll clothing are fabric, satin, and faux fur ( “Barbie Doll Vintage Clothes Identified 1975-1976”). Synthetic fibers in fabric can be composed of nylon and polyester (Gupta). Satin is also made of nylon and polyester (“Satin vs. Sateen: What’s The Difference?”). The faux fur is made of polyester, modacrylic, and acrylic (Okafor). Mattel also uses a water-based paint for their dolls ( “Engineering Barbie”). This paint also contains acrylic and vinyl ( “The Ultimate Guide To Water-Based Paints”). The nylon in the fabric and satin are made of petroleum (“5 Types of Nylon and Their Differences, Uses, and Properties”). The polyester also comes from petroleum (“Polyester”). The modacrylic in the paint is a copolymer made of acrylonitrile and vinyl chloride (Mistry). The acrylic is also made of acrylonitrile (“A Guide to Acrylic Fabric”). Essentially, the synthetic fabrics, satin, and faux fur are derived from polyester; the fabrics and satin both come from nylon, and the faux fur and water-based paint include acrylic. 

Most of the materials in the Monster High doll are composed of PVC. However, PVC poses an environmental threat. As stated before, PVC is built of chlorine. Chlorine is a leading factor of CFCs, which go into the atmosphere and break down the ozone layer (“PVC: The Poison Plastic”). This leads to the furthering of global warming. Another chemical resulting from PVC is dioxin, which is created whenever chlorine chemicals are produced or used. PVC throughout its lifecycle is responsible for the amount of dioxin in the nation, which is extremely toxic and can lead to health damage (“PVC: The Poison Plastic”). Other raw materials required for the Monster High doll are crude oil and petroleum. Both being a fossil fuel, when used for combustion they contribute to the greenhouse gasses that break down the ozone layer (“Petroleum”). 

Moving onto the manufacturing process of the Monster High doll, the plastic materials of the doll body are put into metal molds, after being melted down to liquid at 150 degrees Celsius (“How Dolls Are Made”). The molds used for doll making are made of steel, with the melted plastic being placed in between two halves of the steel molds to form the body of the doll, assuming the shape when air pressure of 80-120 psi is applied (“Plastic Doll”). The doll is then painted with water-based paint. After, it is heated to dry, and then the hair is sewn into the doll head by human workers. The workers will then style the hair, and seamstresses sew the different clothing designs (“How Dolls Are Made”). 

After manufacturing is the distribution process. For packaging the Monster High dolls, Mattel uses recycled content in the paper and wood-fibers for the toy boxes. These contents are also certified by the Forest Stewardship Council. For the window cartons and blister packs, Mattel has increased the use of recycled polyethylene terephthalate (“Sustainable Packaging”). Polyethylene terephthalate is derived from the polymerization of ethylene glycol and terephthalic acid (“Polyethylene Terephthalate”). Once packaging is done, the dolls are then transported to distributing stores. In 2017, Ryder System Inc. pledged their dedication to Mattel’s distribution center in Jonestown, Pa. Ryder used delivery trucks to distribute the many toys by Mattel (“Ryder to Provide Transportation Needs for Mattel at Toy Maker’s New Plant”). The fuel for these trucks is usually distillate fuel (“Use of Energy Explained”). Distillate fuel is usually diesel, which derives from petroleum ( “Distillate Fuel Oil”). Albeit, while Mattel is still working on 100% recycled materials for their packaging, they still use non-renewable fuel for transportation. 

The use, reuse maintenance stage of the dolls does not have any new materials needed, as plastic does not degrade and can last decades. However, it is common for many buyers of the Monster High doll to restyle the dolls, whether with custom outfits made from fabric or satin, or even new saran hair. Though, after the dolls are done being used, they can move onto the recycling and waste management stage. In order to prevent the materials from their toys, Mattel launched Mattel PlayBack. Mattel will recover toys only from their company after buyers are done with them, so that the materials can be recycled to make newer toys. The materials will be downcycled or converted from waste into energy (“Mattel PlayBack and Sustainability”). Though, since most of the materials in the Monster High doll are of plastic, this means that additional virgin materials would be needed in order to maintain its quality and be able to sell on the market (“7 Things You Didn’t Know About Plastic (and Recycling)”). ABS plastic has a low melting point, so it can be easily turned into liquid, and can be melted and extruded multiple times, making it easy to recycle (“ABS Recycling”). EVA on the other hand can be difficult to recycle with most EVA products not being able to be recycled at all (Princy). Vinyl is also very difficult to recycle. Though vinyl can be melted down many times and recycled without it affecting the chain length of its molecules (“Is Vinyl Recyclable? (And Is It Biodegradable?)”). PVC is the least recyclable plastic because of how it contains so many additives (“PVC: The Poison Plastic”). However if the PVC plastics are separated and not mixed with any other plastics when mechanically recycled, then it should allow the recycling process to be easier and the PVC to be turned into a high-quality recyclate (Rubio). Mattel Playback is very beneficial in order to keep plastics from going into landfills and limit the use of crude oil, however it is still needed in order to keep the recycled plastics high quality enough to be market suitable.

It was very difficult to find information about the materials used in the Monster High doll, as there aren’t many articles about the manufacturing process of them. Mattel has very little statements about the process that goes into making specifically the Monster High doll, so most of the information is based on the assumption that they use the same materials from their Barbie doll and other unnamed plastic doll articles. 

Overall, the materials of the Monster High doll body are vinyl, EVA, ABS, and PVC plastics. The hair is made from saran fibers and tinsel, and the face is drawn with water-based paint. The clothes are from synthetic fabric, satin, and faux fur. The vinyl, ABS, PVC, and tinsel are derived from oil, then EVA and ABS are from petroleum. The fabric, satin, and faux fur are made of polyester, while the fabric and satin are made of both polyester and nylon, and the faux fur and water-based paint were from acrylic. The manufacturing stage consisted of steel molds and human workers. The distribution and transportation stage included recycled content in paper and wood packaging, and recycled polyethylene terephthalate for the window cartons. The fuel for the delivery trucks was distillate fuel which derived from petroleum. The recycle and waste management stage is Mattel’s toy recovery program which would repurpose Mattel products’ materials, but in order to recycle plastics, virgin materials are to be added. Therefore, Mattel’s Monster High doll has many drawbacks for environmental safety with most of their materials derived from non-renewable sources, however Mattel is attempting to make up for those by using more recycled materials from making new toys to the packaging. 

Bibliography

Arizona Painting Company Team. “The Ultimate Guide To Water-Based Paints | Arizona Painting Company.” Arizona Painting Company, 9 Aug. 2017, https://arizonapaintingcompany.com/ultimate-guide-water-based-paints/.

British Plastics Federation Team. “Polyvinyl Chloride PVC.” British Plastics Federation, https://www.bpf.co.uk/plastipedia/polymers/PVC.aspx. Accessed 12 Mar. 2023.

CFDA Team. “Polyester | Materials Index | CFDA.” Council of Fashion Designers of America, https://cfda.com/resources/materials/detail/polyester. Accessed 12 Mar. 2023.

Coda Plastics Team. “Life in Plastic: How Mattel Created Its New, Diverse Line of Barbie Dolls.” Coda Plastics, 2 May 2016, https://www.coda-plastics.co.uk/blog/life-in-plastic-how-mattel-created-its-new-diverse-line-of-barbie-dolls.

Conserve Energy Future Team. “Is Vinyl Recyclable? (And Is It Biodegradable?) - Conserve Energy Future.” Conserve Energy Future, https://www.conserve-energy-future.com/is-vinyl-recyclable.php. Accessed 12 Mar. 2023.

Curbell Plastics Team. “EVA Material Properties | Curbell Plastics.” Curbell Plastics, https://www.curbellplastics.com/Research-Solutions/Plastic-Material-Properties/EVA-Properties. Accessed 12 Mar. 2023.

DN Staff. “Engineering Barbie.” Designnews.Com, 18 Dec. 2000, https://www.designnews.com/materials-assembly/engineering-barbie.

Doll Reference Team. “Barbie Doll Vintage Clothes Identified 1975-1976.” Doll Reference, https://www.dollreference.com/barbie_vintage_fashions1975-1976.html. Accessed 9 Feb. 2023.

Emily. Monster High Dolls by Mattel. https://www.toyboxphilosopher.com/2012/01/monster-high-dolls-by-mattel.html. Accessed 9 Feb. 2023.

Encyclopedia Britannica Editors. “Polyethylene Terephthalate | Britannica.” Britannica, https://www.britannica.com/science/polyethylene-terephthalate. Accessed 12 Mar. 2023.

Energy Information Administration Team. “Distillate Fuel Oil - U.S. Energy Information Administration (EIA).” U.S. Energy Information Administration, https://www.eia.gov/tools/glossary/index.php. Accessed 12 Mar. 2023.

—  “Use of Energy Explained” U.S. Energy Information Administration, 17 June 2022, https://www.eia.gov/energyexplained/use-of-energy/transportation.php.

Fabric House Nashville Team. “Satin vs. Sateen: What’s The Difference?” The Fabric House Nashville, 22 Aug. 2018, https://fabrichousenashville.com/satin-vs-sateen-whats-difference/.

Greenpeace Team. “PVC: The Poison Plastic.” Greenpeace, 18 Aug. 2003, https://www.greenpeace.org/usa/wp-content/uploads/legacy/Global/usa/report/2009/4/pvc-the-poison-plastic.html.

Gupta, Mira. “How Synthetic Fabrics Were Invented and Why They Are Not Sustainable.” Marasim - Sustainable Textile, Craftsmanship, Luxury, 15 Nov. 2021, https://blog.marasim.co/how-synthetic-fabrics-are-made-and-why-they-are-not-sustainable/.

Harvey, Ailsa. How Tinsel Is Made – How It Works. 12 Jan. 2019, https://www.howitworksdaily.com/how-tinsel-is-made/.

How Dolls Are Made | I Didn’t Know That. Directed by National Geographic, 2013. YouTube, https://www.youtube.com/watch?v=W2_FF1paBew.

How Products are Made Team. “Plastic Doll.” How Products Are Made, http://www.madehow.com/Volume-5/Plastic-Doll.html. Accessed 12 Mar. 2023.

Mattel Team. “Mattel PlayBack and Sustainability| Mattel.” Mattel Shop, https://shop.mattel.com/pages/playback. Accessed 12 Mar. 2023.

---. “Sustainable Packaging | Mattel, Inc.” Mattel Corporate, https://corporate.mattel.com/sustainable-packaging. Accessed 12 Mar. 2023.

Mistry, Hetal. “Modacrylic Fibre.” Textile Magazine, Textile News, Apparel News, Fashion News, 18 July 2020, https://textilevaluechain.in/in-depth-analysis/articles/textile-articles/modacrylic-fibre/.

Okafor, Jennifer. “What Is Faux Fur Fabric? Sustainability, Pros and Cons.” Trvst, 17 Jan. 2023, https://www.trvst.world/sustainable-living/fashion/faux-fur-fabric-sustainability/.

Olympus Life Science Team. “Saran Fiber | Olympus LS.” Olympus Life Science, https://www.olympus-lifescience.com/en/microscope-resource/galleries/polarizedlight/pages/saranlarge/. Accessed 12 Mar. 2023.

Princy, A. J. “Ethylene Vinyl Acetate Resins: Properties, Advantages, Applications, and Their Recyclability.” Research Dive, 25 July 2022, https://www.researchdive.com/blog/ethylene-vinyl-acetate-resins-properties-advantages-applications-and-their-recyclability.

PVC Forum South East Europe Team. “PVC Additives - PVC.” PVC Forum South East Europe, http://www.seepvcforum.com/en/content/9-pvc-additives. Accessed 12 Mar. 2023.

Reclaim Plastics Team. “ABS Recycling - Reclaim Plastics.” Reclaim Plastics, 23 July 2021, https://reclaimplastics.com/materials-we-recycle/abs-recycling/.

Rubio, Michelle Rose. “Everything You Need to Know About PVC Recycling.” BioEnergy Consult, 16 June 2022, https://www.bioenergyconsult.com/recycling-polyvinyl-chloride/.

Sailrite Team. “A Guide to Acrylic Fabric.” Sailrite, https://www.sailrite.com/A-Guide-to-Acrylic. Accessed 12 Mar. 2023.

Sedaghat, Lilly. “7 Things You Didn’t Know About Plastic (and Recycling).” National Geographic, 4 Apr. 2018, https://blog.nationalgeographic.org/2018/04/04/7-things-you-didnt-know-about-plastic-and-recycling/.

Team Xometry. “5 Types of Nylon and Their Differences, Uses, and Properties.” Zometry, 14 June 2022, https://www.xometry.com/resources/materials/types-of-nylon/.

Transport Topics Team. “Ryder to Provide Transportation Needs for Mattel at Toy Maker’s New Plant.” Transport Topics, 1 Aug. 2017, https://www.ttnews.com/articles/ryder-provide-transportation-needs-mattel-toy-makers-new-plant.

What Is Vinyl Team. “What Is Vinyl? Vinyl Material Properties, Discovery & Applications” What Is Vinyl, https://www.whatisvinyl.com. Accessed 12 Mar. 2023.

World Wide Fund for Nature Team. “Petroleum.” WWF,https://wwf.panda.org/discover/knowledge_hub/teacher_resources/webfieldtrips/climate_change/petroleum/. Accessed 12 Mar. 2023.

Grace Asuncion 

DES 040A

Christina Cogdell

March 7, 2023

The Energy Use of the Production of Monster High Dolls

Introduction

When it comes to products that we use on a daily basis, there is not much thought about how these products came to be. People don’t think about the energy input or the specific materials that are used, especially with children. Take one of Mattel’s famous doll franchises, Monster High dolls, as a prime example. In Wohlwent and Carmen’s study, “Monster High: Converging Imaginaries of Girlhood in Tweens’ Digital Doll Play”, they mentioned how the popularity of these dolls is due to the cross-media that is produced to market these dolls. Monster High dolls have become a stable for children’s childhood. The main premise focuses on characters based on monster movies and tales. Consumers have become absorbed by the branding of these dolls that they overlook the actual process for these dolls. There is an abundance of different types of energy being used during the raw material acquisition process and the product manufacturing process. With the amount of energy usage and the impact on the environment, there are signs of sufficient use of energy for the production of Monster High Dolls. 

Raw Material Acquisition 

Before the start of the production of these dolls, there has to be a production for the raw materials that are going to be used during the manufacturing process of Monster High dolls. However, in terms of energy consumption, it’s something that people don’t see. Overviewing the amount of energy that is being used, will express the importance and the reliability that Mattel has for the production of their infamous franchise. 

Vinyl and plastic are one of the most vital materials that are needed for the production of Monster High Dolls. Plastic and Vinyl are cumulated of PVC. This material makes up the mass majority of the doll's body. However,  there is a high usage of chemical energy and thermal energy consumption during this process of producing PVC. In Teknorapex’s article, “How is PVC Made, Anyway?”, they talk about ethylene, a chemical that is used for PVC, is from oil. They further explain the process of thermal cracking. Thermal cracking is the process in which hydrocarbons are increasing heat and temperature in order to break down molecular bonds. This process uses chemical and thermal energy. Using heat to change the chemical composition of the oil helps extract the raw material that is needed for the chemical makeup of PVC. To further explain energy utilization, the reaction of the heat from this process changes the weight of the chemicals. For the use of thermal energy, the form of the material is changed from a gas to a liquid. Another chemical that is needed for PVC is chlorine, which is found in sea salt. There is an extraction process in order to separate the chlorine from the sea salt called electrolysis. According to the Office of Energy Efficiency and Renewable Energy, “Electrolysis is the process of using electricity to split water into hydrogen and oxygen.”. Electrolysis uses thermal and electrical energy. Use electricity to extract the molecules, which separate the chlorine. Afterward, there would be a chemical reaction between the ethylene and the chlorine in order to produce dichloride or EDC, which was mentioned in “How Is PVC Made, Anyway?”. Then with the EDC, it goes through thermal cracking once more to produce VCM, vinyl chloride monomer. With the VCM, it goes through polymerization. Polymerization is a process of small molecules combining with other small molecules to produce a polymer. This process uses chemical energy as there is a chemical reaction occurring to create the PVC resin that would be used for the plastic molding process during production. 

Another vital material that is needed for the production of Monster High Dolls is the saran fiber that is used to produce the hair for the dolls. Saran fiber is made up of Polyvinylidenece chloride copolymer by a process called melt spinning (Asahi Kasei Home Products Corporation, 2023). Melt spinning uses thermal and kinetic energy and is used to produce synthetic fibers. The article, “Melt Spinning Textile” further explains the process of melt spinning. First, the plastic is heated and then melted into a thick consistency, which gets turned into a string that is spun by a pump. With the fiber cooled down, it would get turned into a yarn-like material, which would be used to implant the hair onto the doll’s head. Overall this process relies heavily on the use of thermal and kinetic energy. 

Clothes are what bring out a Monster High doll’s individuality and the acquisition of faur fur, synthetic fabric, and satin are all that bring the dolls that pop of personality. First, faux furs, are composed of polymers and chemical energy is used to produce the fibers. In How Products are Made’s article, “Fake fur” along with the chemical reaction to produce the fibers there is a whole process to actually produce the fur. The article, it more further into how fake fur is being made. In the article, there is a weaving process that is used to loop the fibers into the premade backing, in which kinetic energy would be used. While doing research on the other processes on how the other fabrics are manufactured, the majority of the time they go through similar processes and usage of the same type of energy. However, there is no further information found on what type of primary source is used for the production of these materials. The only information that is known on the use of electricity, would be a secondary source. 

Product Manufacturing

With all of the raw materials that are needed, it’s time to overlook the energy usage for the actual production of Monster High Dolls. The PVC resin is used to make the mold of the doll’s body.  In “Plastic Dolls” the article thoroughly explains the molding process. During this process, thermal energy and kinetic energy are used to heat the liquid compound inside the molding machine. In order to make sure the liquid resin into the dolls that we all know and love, it has to be rotated during the heating process to be shaped in the cavity of the mold. Afterward water and air would help the mold be cooled down, which would be a use of thermal energy. 

Having the general base of the dolls, there is a need to have the doll’s unique hair.  In the news article. “Doll Factory Workers Reveal How They Add Hair and Eyeballs in ‘Creepy’ Video, shows how the hair gets implemented on the dolls’ heads. The articles state how there is a fast needle that is used. With the saran fiber, there is a use of kinetic energy to lock the fiber onto the head. This process is would use human labor as they decide on the head to make sure the saran fiber would provide full coverage for the hair. The machine that would actually lock the hair onto the doll’s scalp would be using electrical energy. 

As for the details of the doll, there would be a use of paint, which would be made up of a kinetic process of mixing various chemicals together with added pigment. For how the details of the doll would be applied, would be used by spray paint, which is an airbrush method. This process would also use kinetic energy. For the clothes of the dolls, it would be through a sewing process, as that would be a kinetic use, as the string would be weaved onto the faux fur, synthetic fabrics, and satin. 

Transportation and Distribution

The transportation and distribution of Monster High dolls is a worldwide process. In “Mattel goes local in Brazil, India”, it states that 74% of Mattel’s production is in China and the rest of the percentage is in Indonesia, Malaysia, Mexico, and Thailand. There is no solidified information on how much energy is used or the exact distances traveled. However, we can give a rough estimate. From China, it takes 7,233 miles to travel to the USA. To Indonesia it’s 9,291 miles, Malaysia it’s 9,358 miles, Mexico it’s 1,014 miles, and to Thailand, it’s 8,614 miles. All of this data is based on Google search and there are still variables that this isn’t reliable to use to refer to the amount of energy that is used. This data is a general proximity between the different countries and this is only for the transportation of Monster High dolls. The type of fuel used for the ships would be distillate fuels, according to  “Use of energy explained: Energy use for transportation”. Distillate fuels would be a type of fossil fuel that could contribute to greenhouse gas emissions and that’s for international transportation alone. In regards to the distribution of Monster High dolls, it would be a nationwide process, as different delivery trucks would travel all over the country. There are many stores that would hold these products in their stores so having an estimated distance would be challenging. In the same article, “Use of energy explained: Energy use for transportation”, trucks also use distillate fuels as well. Having to cumulate the distance traveled and the type of energy that uses for transportation, we can only estimate a large amount of insufficient energy usage there is just for the transportation and distribution of Monster High dolls. 

Maintenance and Final Disposal

After all the amount of energy that has been used, the Monster High dolls are now ready to be in the hands of the consumer. There was a lack of resources published that further describe the energy usage for these dolls. However, there is not much to work with in terms of what sources of energy are used. The main source that would be thought of would be the use of kinetic energy. Having to brush the doll’s hair, having to clean, and maintain cleanliness would be all in the kinetic effort. Having to have further research on the maintenance with kinetic energy would seem to be a useless amount of time to invest in

For Monster High dolls, when there is no only use for them the consumer would unfortunately just throw the doll away in the trash. The source of energy consumption in this process would be the thermal and kinetic use of breaking down the doll into pieces that would be easier for disposal. Chemical energy would be used as the molecules would naturally break down, as well.

Conclusion 

Overviewing the whole life cycle of Monster High dolls shows the amount of energy that is utilized for the usage of plastic. Having this high utilization of energy, would heavily affect the environment and contribute to climate change. However, Mattel published a website to provide a statement in regards to what they are going to do to provide sufficiency in their production process for their products. In terms of energy, they are reducing the amount of energy consumption. Based on the graph in the same following article, “Operating with Care”, shows that in 2019 there was a total of 411,954 energy used and in 2021, there was a total of 370,467 energy used. So, Mattel is reducing the amount of energy, and based on this data, the amount could decrease as the years go by. 

For the overall research on energy consumption, there were issues with finding the process for Monster High dolls themselves. Most of the research was used on Barbie dolls, as they are another doll produced and manufactured by Mattel. Having to refer to the process of Monster High dolls to Barbies may show inaccuracy for the actual process. However, given the popularity of these dolls and the demand, Mattel would prefer to keep this type of information to themselves. Monster High dolls have become stable for our generation in expression, so having to hide such information from potential competitors would be vital for Mattel. 

Bibliography

Flood, Rebecca. “Doll Factory Workers Reveal How They Add Hair and Eyeballs in ‘Creepy’ Video.” Newsweek. 2021. https://www.newsweek.com/doll-factor-workers-reveal-how-add-hair-eyeballs-creepy-video-1610110

https://www.polyestermfg.com/melt-spinning-in-textile/

“Fake Fur”. How Products are Made. 2023

http://www.madehow.com/Volume-3/Fake-Fur.html

“How is PVC Made, Anyway?” Teknor APEX. March 31, 2017. https://www.teknorapex.com/the-pvc-production-process

“Hydrogen Production: Electrolysis”. Office of Energy Efficiency & Renewable Energy https://www.energy.gov/eere/fuelcells/hydrogen-production-electrolysis#:~:text=Electrolysis%20is%20the%20process%20of,a%20unit%20called%20an%20electrolyzer.

“Operating With Care”. Mattel. 2022. https://corporate.mattel.com/operating-with-care

“Plastic Doll.” How Products are Made. 2023 http://www.madehow.com/Volume-5/Plastic-Doll.html

Skariachan, Dhanya. “Mattel goes local in Brazil, India.” Reuter. 2013. https://www.reuters.com/article/mattel-manufacturing/mattel-goes-local-in-brazil-india-idINDEE91D0IK20130214

“Use of energy explained: Energy use for transportation” Eia.  2022. 

https://www.eia.gov/energyexplained/use-of-energy/transportation.php

“What’s PVDC fiber “Saran” Asahi Kasei Home Products Corporation. 

https://www.asahi-kasei.co.jp/sarannet/en/whatsaran.html#:~:text=Saran%E2%84%A2%20fiber%20is%20manufactured,consumer%20products%20to%20industrial%20applications.

http://www.madehow.com/Volume-3/Fake-Fur.html

Wohlwend, Karen E. & Medina, Carmen L. “Monster High: Converging Imaginaries of Girlhood in Tweens’ Digital Doll Play”. Indiana University. 2015. https://scholarworks.iu.edu/dspace/bitstream/handle/2022/22828/2017%20Wohlwend%20Medina%20Monster%20High--Converging%20imaginaries%20of%20girlhood.pdf?sequence=1&isAllowed=y

Sarah Liang

Professor Cogdell

DES 40A Winter 2023

16 March, 2023

Monster High Doll Life Cycle – Waste

Monster High dolls are a popular line of unique, monster-like, high-school age dolls Mattel manufactures. This essay addresses the life cycle of these dolls, from material acquisition to final disposal, specifically the waste that is output from each stage. Though it is typically assumed that throwing away toys is the end of their lifeline and the only source of waste, that is not the case. The piling landfills from disposal are only a facet to the amount of waste Mattel Monster High dolls generate.

== Raw Materials Acquisition ==

Even at the beginning of a Monster High doll’s life cycle, raw material acquisition, waste is being generated. In the production of PVC plastic, which is by far, the main material used in manufacturing Mattel dolls, byproducts such as petroleum coke, hydrogen, and oxygen are released through 2 processes called thermal cracking and electrolysis.

To explain further, PVC is made from 2 main primary materials, salt and oil, specifically the ethylene from oil and chlorine from salt. 

In order to obtain the ethylene particles from liquid petroleum (also known as crude oil), extreme pressure and heat is applied (thermal cracking) to identify ethylene’s unique molecular weight in the oil and for it to be separated and then extracted (Teknor Apex, 2017). In addition to producing ethylene, this process also creates a carbon-rich substance that builds up in the walls of the furnace, called petroleum coke. This material is incredibly detrimental to our environment and ourselves because it not only releases immense amounts of CO2 emissions when burned as fuel but is also linked to several health issues, one being cancer (Geertsma, 2013). 

Chlorine in sea salt, the other main ingredient in PVC, is obtained through electrolysis, which uses electricity to alter the molecular structure of sea water to separate the chlorine particles. The byproducts produced from which are hydrogen and oxygen.

Finally, following the acquisition of these raw materials, ethylene and chlorine are combined and passed through an additional stage of thermal cracking and polymerization to create PVC resin, the basis of all vinyl compounds and thus the foundation for most parts of a Monster High doll (Teknor Apex, 2017). 

== Manufacturing ==

From the body and hair to even the paint and packaging, practically every aspect of Mattel dolls contain some form of plastic or polyvinyl chloride plastic (pvc aka vinyl) compound. 

Barbie, Mattel’s most famous doll and a similar product to Monster High dolls clearly reflects this. “Her head is made from a vinyl compound, her arms from EVA (ethylene-vinyl acentate), her torso from an engineering thermoplastics polymer called ABS (acrylonitrile-butadiene-styrene) and her legs from polypropylene and PVC,” all of which are plastic or have some sort of plastic component in them (Coda Plastics, 2016). 

As for clothes, synthetic fabrics, such as polyester, nylon, and acrylic, all of which are some form of plastic, are commonly used for doll-making (Resnick, 2018). Mattel also utilizes saran and nylon for the hair on Barbie, which is, once again, a synthetic material made with plastic-based fiber (My Pretty Dolls, 2022). Even the water-based paint on these dolls contain microscopic particles of plastic acrylic and vinyl (Upstyle, 2014). And since Barbie and Monster High dolls are manufactured at the same company, it can be assumed that Monster High dolls utilize the same or similar amounts of plastic in their composition. 

To produce the previously mentioned body parts of a doll, plastic molding is required. Liquid plastic material is poured into the metal molds and rotated to allow the material to fill all sides of the mold. When cooled down, the finished part is then extracted from the mold. Each of these pieces are then joined together to create the basic structure of the doll. “Any excess material produced during the molding process is usually discarded, since it cannot be recycled back into the process. The composition of the virgin material would be affected [and] would change the quality and color of the doll” (Sheppard).

Scraps of fabric, hair, and paint are also types of waste produced in the manufacturing stage of a Monster High doll’s life cycle, and are assumed to be discarded like the excess plastic from molding the body of the doll. 

Adding onto the waste generated by simply utilizing materials to make dolls, the factories that pump out such products rely on burning fuels to function, which pollute the air with carbon dioxide and other emissions in the process (Rutledge, 2022). 

== Distribution and Transportation == 

Closely following the manufacturing stage, transportation is another main contributor to the total waste produced by Monster High dolls. The shipping of materials between factories, to shops, and to homes, in itself, produces an immense amount of emissions that contributes to global warming. Mattel would need freight trucks to ship cargo, delivery trucks to send out online purchases, and consumers would need their own vehicles to drive to retail stores. All of these are considered modes of transportation and all release airborne waste, in the form of carbon dioxide emissions, into the atmosphere.  It is said that “the largest source of emissions of carbon dioxide (CO2 , the most common greenhouse gas) in the United States is the transportation sector” (Shirley, 2022). The distribution of Monster High dolls contributes to this waste. 

== Use ==

Even after manufacturing, purchasing, and the shipment of these dolls, there is still waste being produced during their use. The cardboard and plastic packaging the doll came in still needs to be disposed of. Not only does the packaging waste contribute to our society’s expanding landfills but it also impacts the carbon footprint of the environment. This is because, to make the boxes for Monster High dolls, and likely most of Mattel toys, many trees are cut down for paper, increasing the amount of carbon emissions we have in our atmosphere (KariO, 2011). 

== Recycling ==

Up to now, every previous stage of the Monster High doll’s life cycle has produced some sort of waste. But there is some saving grace: PVC can be recycled. It is, in fact, “one of the most advanced processes in the mechanical recycling world” because of the large amounts of PVC production and usage in our current society. It can be recycled in 3 ways: reground into new plastic, turned into plastic powder, or shaped into pellets for reuse. The only downside is that its recycling process does not go through the recycling bin as most other recyclable materials do. It must be sent to a special plastics recycling center for it to be properly cleaned, separated, and reused. If simply discarded into landfills, plastic will break down into smaller particles that have a toxic effect on the environment and its organisms (Clark, 2022). 

To combat this, Mattel is encouraging recycling of materials for their products, as well as reducing plastic packaging waste. The company has since labeled 33 of their toys as sustainable and made from recycled materials. For instance, a new Barbie was manufactured using recycled plastic waste, and hopefully Monster High will be following in its footsteps. Mattel’s goal by 2030 is to make their entire product line recyclable, while also reducing plastic in their packaging by 25% per product. They are also aiming to make their toys carbon neutral, by using more sustainable materials. Though these are still goals, Mattel has shown progress and incentive to reduce the amount of harmful waste they put out into the environment (Woody, 2022) (Mattel). 

== Waste Management ==

The real end of a Monster High doll’s life cycle is ultimately its final disposal into a landfill. Toys have a finite life span, as they are “designed to ‘spark joy’ but often end up as waste when a child’s play interests change” (Robertson-Fall, 2020). In 2019 it was estimated that “80% of all toys end up in landfill, incinerators, or the ocean.” Therefore, when a child decides they do not like or have outgrown the doll, it will most likely end up in the trash, and then carried over to a landfill, contributing to the waste the production of the doll generated (Robertson-Fall, 2020).

But this plastic might not remain in our landfills. It can move with the wind, pollute oceans and be ingested by marine animals and then humans, or it can be broken down into microscopic pieces and spread all over the world. And since plastic does not decompose, it will remain in our world forever (Plastic Soup Foundation, 2020).

Adding up all the waste generated from each and every one of the five life cycle stages described throughout this paper, it is shown that final disposal is only a fraction of the total waste produced during the life span of Mattel’s Monster High Doll. 

== Works Cited == 

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