Consumers purchase products with the expectation that the product will be safe and will not cause injuries. However, a design defect can turn a seemingly safe product dangerous if not addressed by manufacturers. A recent report by NPR suggests that this may be the case for some instant noodle soups.

NPR reported that the poor design of some instant noodle soups make them incredibly easy to spill and can lead to serious burn injuries, especially in children. The problem is that the packing is designed to be tall and lightweight, which can easily tip over into a child's lap.

Once tipped over, the hot noodles often stick to the skin, causing deep burns that are much worse than those caused by hot liquids alone. Sometimes children who have been burned by instant noodle soups require surgery, and permanent scarring and nerve damage can result, NPR reported.

Out of a dozen hospitals interviewed by NPR, eight reported that they see burn injuries caused by instant noodle soups several times per week, and children are the most frequent victims. At least one hospital reported seeing even more than that, especially during the colder months.

The director of the burn unit at University of Southern California's County Hospital in Los Angeles said that his hospital sees at least two to three patients each week who have been burned by the instant noodle soups. He calls the soups "uniquely troublesome" as there is no other injury he sees more frequently caused by poor product design.

In 2007, a researcher published a study that analyzed the noodle soup burns and packaging. The researcher said that what it comes down to is how easily a cup of hot noodle soup will tip. Unfortunately, he found that one of the most popular and least expensive brands on the market was the most prone to tipping and causing burns.

Cup Noodles, which is manufactured by Nissin, was found to spill when tipped at a 22 degree angle. This can be compared to a brand called Nicecook which takes an angle of 64 degrees to tip over.

Ultimately, the researcher said that with a simple packaging redesign, Cup Noodles could become much safer.

Source: NPR, "Why Burn Doctors Hate Instant Soup," Mara Zepeda, Dec. 5, 2011