Case Study “Box for you”

“Box for you” – Project support from concept to mass production

In many product developments, the choice of materials, technical feasibility and the requirements for subsequent use play a key role. This was also true for the development of the “Box for you” by a Swiss start-up. In this case study, we demonstrate how the customer, in collaboration with BARLOG Plastics, was able to bring their product to market quickly, reliably and cost-effectively through the right choice of materials and comprehensive development services.

Project description

‘Box for you’ is a project realised by a young Swiss start-up in collaboration with BARLOG Plastics. BARLOG Plastics supported the company from the initial product idea through development right up to market launch.

The ‘Box for you’ is a plastic box comprising several plastic components. It can be filled with food or other items and is used, for example, to provide refreshments for participants on guided hikes in Switzerland. The box is available in various colours and designs and can be customised to meet specific customer requirements, for example as a promotional item or for specific brand presentations.

Material selection

KEBALLOY® ECO E302 natural was used for the project. This is a material based on processed PET recyclate from used PET bottles. The material meets the requirements for food-contact applications and offers the mechanical and optical properties necessary for the application.

The material was selected taking into account the product’s technical requirements as well as the customer’s request to use a material based on recycled raw materials.

Development services

BARLOG Plastics supported the start-up throughout various phases of the project. This began with consultancy regarding material selection and product concept. Subsequently, a production-ready design was created and further developed through several rounds of optimisation.

Injection moulding simulations were carried out to ensure the success of subsequent production. This enabled potential weaknesses to be identified at an early stage and the geometry of the components to be specifically optimised.

The result was a design in which the interlocking components are precisely matched to one another. This ensures that the box closes securely and prevents viscous foodstuffs from leaking out.

Prototypes and pre-production run

A total of four prototype moulds were produced for the box, lid, handle and clip as part of the development process. BARLOG Plastics then manufactured a pre-production run of 1,000 units in various colours.

The pre-production run enabled the customer to test the product under real-world conditions, gather user feedback and identify potential areas for optimisation before small-batch production began.

Small-batch production and assembly

As part of the so-called ‘bridge tooling’ process, up to 10,000 boxes were manufactured.

In addition to manufacturing the plastic parts, BARLOG Plastics also handled the assembly of the base, handle and clip, as well as the printing on the clip. Both the ‘Box for you’ logo and the indication that the product is made from recycled PET were applied.

Advantages of working with BARLOG Plastics

Comprehensive project support

From material selection and design right through to production and assembly, the customer received all services from a single source.

Component optimisation tailored to development

Through a combination of design optimisation and injection moulding simulation, the functionality of the box was specifically improved and preparations were made for subsequent series production.

Rapid validation through prototypes and pre-series production

The production of prototype moulds and a pre-series run enabled the product to be tested at an early stage under real-world conditions.

Materials expertise

By selecting a material suitable for food contact based on recycled PET, the customer’s requirements regarding material properties and product design were met.

Conclusion

The collaboration between the Swiss start-up and BARLOG Plastics demonstrates how innovative product ideas can be efficiently realised through a combination of materials expertise, development services and manufacturing expertise.

From the initial concept phase through prototype development to small-batch production, the project was continuously supported and optimised. The result is a market-ready product solution that meets the technical, functional and regulatory requirements of the application and has been successfully launched onto the market.