Case study – Sustainable product development in prototype injection molding: The sealable reusable tray

As part of this project, BARLOG Plastics GmbH worked closely with reCup GmbH to comprehensively test the design, handling, and material properties of the product using prototype injection molding. The aim was to intensively test the sealable reusable tray before the start of series production and to check its practical suitability. reCup GmbH’s vision is to establish a sustainable and circular ecosystem – for a world without single-use packaging. To this end, an innovative deposit system for reusable tableware has been developed that maintains the familiar “to-go philosophy” while offering a simple, environmentally friendly reusable alternative.

Project description: Component and requirements

As part of a collaboration between BARLOG Plastics GmbH and reCup GmbH, the development of a sustainable reusable tray – the sealable reusable tray – was driven forward. The aim of the project was to evaluate the component in terms of design, handling, and material behavior prior to series production. The tray was manufactured using prototype injection molding in order to gain quick and practical insights into its geometry, functionality, and manufacturability.

Challenges:

• Small series: Instead of investing directly in a series production tool, the product was to be tested in a small series first. This allowed flexible adaptation of the component geometry and an efficient test phase without incurring high tooling costs. The aim was to gather sound knowledge for later series production.
• Requirements: The tray had to meet both functional and aesthetic requirements. The aim was to develop a solution that was approved for use in the food industry.
• Focus on sustainability: A key objective of the project was to contribute to the reduction of single-use packaging. The sealable reusable tray is part of a well-thought-out deposit system that combines the convenience of to-go offerings with the advantages of a circular reusable system. The development phase therefore placed not only technical but also ecological demands on the product.

Solution approaches and process design

1. Small series production using prototype injection molding

The small series for preliminary testing was produced using prototype injection molding. Prototype injection molding is a method for the fast and cost-efficient production of functional plastic components in small quantities. It uses simplified or temporary tools, usually made of aluminum or softer steel, which are significantly cheaper and faster to produce than series tools.

2. GMP manufacturing

Good Manufacturing Practice (GMP) manufacturing has enabled us to meet the high quality and safety standards required by the food industry. GMP is an internationally recognized set of rules designed to ensure that products:

1. are of consistent high quality 3. are free from contamination

2. are safe for consumers 4. are traceable

Production was carried out in accordance with GMP guidelines and Regulation (EC)

No. 2023/2006 on good manufacturing practice for materials and articles intended to come into contact with food.

3. Focus on sustainability

As sustainability played a central role throughout the project, the manufacturing process was also designed accordingly. In addition, a recyclable material (virgin PP) was used to further minimize the project’s ecological footprint.

Results and findings

The project illustrates how the use of prototype injection molding can provide practical tests and valuable insights for later series production:

• Realistic functional testing: The early production of prototype parts enabled comprehensive testing under real conditions. This was particularly important with regard to the handling, stability, and material behavior of the tray.
• GMP production: The shell was developed with the aim of meeting both functional and aesthetic requirements. It is particularly noteworthy that the shell is now approved for use in the food industry, meaning that it meets the high safety and hygiene requirements. These findings underscore the importance of taking both technical and regulatory requirements into account from the outset of product development in order to ensure broad applicability and acceptance.
• Sustainable development: The use of a recyclable material enabled the project to meet its sustainability requirements.

Advantages of working with BARLOG Plastics

1.Flexible and cost-efficient prototype production: The use of prototype injection molding enabled fast and cost-efficient small-batch production. This method made it possible to test the component in a practical environment and gather valuable insights for later series production without incurring high tooling costs.

2.High quality standards through GMP manufacturing: Thanks to Good Manufacturing Practice (GMP) manufacturing, BARLOG Plastics ensured that the developed products meet the highest quality and safety standards of the food industry. This enabled complete traceability, consumer safety, and compliance with strict hygiene requirements.

3.Sustainability as a central project goal: With a clear focus on sustainability, BARLOG Plastics relied on environmentally friendly solutions throughout the entire project. The recyclable material provided by reCup GmbH helped to reduce the ecological footprint compared to single-use packaging.

Conclusion

The project shows how innovative products can be efficiently realized through forward-looking planning, flexible prototype development, and a sustainable mindset. The insights gained provide a valuable basis for the implementation of further sustainable packaging solutions in the reusable system.