The BARLOG Plastics diary
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Case Study – Development of a sealable reusable container using prototype injection moulding
As part of this project, BARLOG Plastics GmbH worked in close collaboration with reCup GmbH to comprehensively test the product’s design, handling and material properties using the prototype injection moulding process. The aim was to subject the sealable reusable tray to intensive testing prior to the start of series production and to assess its suitability for practical use. reCup GmbH aims to provide a reusable system for serving food and drinks. To this end, a deposit system for reusable tableware was developed, combining the familiar ‘to-go’ experience with a reusable alternative.
Project description: Component and requirements
As part of a collaboration between BARLOG Plastics GmbH and reCup GmbH, the development of a reusable tray with a sealing function was driven forward. The aim of the project was to evaluate the component in terms of design, handling and material behaviour prior to series production. The tray was manufactured using a prototype injection moulding process in order to gain rapid, practical insights into its geometry, functionality and manufacturability.
Challenges
Small-batch production
Rather than investing directly in a production mould, the product was first to be tested in a small batch. This allowed for flexible adaptation of the component’s geometry and an efficient testing phase without high moulding investment. The aim was to gain sound insights for subsequent mass production.
Requirements
The tray was required to meet both functional and aesthetic requirements. Furthermore, the aim was to develop a solution suitable for contact with food and compliant with the relevant regulatory requirements.
Requirements for materials and the usage concept
A key project objective was to implement the requirements of a reusable system. The sealable reusable tray forms part of a deposit scheme that combines the use of takeaway services with a reusable packaging solution. Accordingly, both technical and application-specific requirements had to be taken into account.
Approaches and process design
1. Small-batch production using prototype injection moulding
The small-batch production was realised using the prototype injection moulding process. This process enables the rapid and cost-effective manufacture of functional plastic components in small quantities. It utilises simplified or temporary moulds, usually made of aluminium or softer steel, which can be produced significantly faster and more cost-effectively than production moulds.
Image 1: Tool for the sealable reusable tray
As part of this project, BARLOG Plastics GmbH worked in close collaboration with reCup GmbH to comprehensively test the product’s design, handling and material properties using the prototype injection moulding process. The aim was to subject the sealable reusable tray to intensive testing prior to the start of series production and to assess its suitability for practical use. reCup GmbH aims to provide a reusable system for serving food and drinks. To this end, a deposit system for reusable tableware was developed, combining the familiar ‘to-go’ experience with a reusable alternative.
Project description: Component and requirements
As part of a collaboration between BARLOG Plastics GmbH and reCup GmbH, the development of a reusable tray with a sealing function was driven forward. The aim of the project was to evaluate the component in terms of design, handling and material behaviour prior to series production. The tray was manufactured using a prototype injection moulding process in order to gain rapid, practical insights into its geometry, functionality and manufacturability.
Challenges
Small-batch production
Rather than investing directly in a production mould, the product was first to be tested in a small batch. This allowed for flexible adaptation of the component’s geometry and an efficient testing phase without high moulding investment. The aim was to gain sound insights for subsequent mass production.
Requirements
The tray was required to meet both functional and aesthetic requirements. Furthermore, the aim was to develop a solution suitable for contact with food and compliant with the relevant regulatory requirements.
Requirements for materials and the usage concept
A key project objective was to implement the requirements of a reusable system. The sealable reusable tray forms part of a deposit scheme that combines the use of takeaway services with a reusable packaging solution. Accordingly, both technical and application-specific requirements had to be taken into account.
Approaches and process design
1. Small-batch production using prototype injection moulding
The small-batch production was realised using the prototype injection moulding process. This process enables the rapid and cost-effective manufacture of functional plastic components in small quantities. It utilises simplified or temporary moulds, usually made of aluminium or softer steel, which can be produced significantly faster and more cost-effectively than production moulds.
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