First

The Challenge:

We often hear from customers looking for a more efficient alternative to standard plastic reels—something versatile, functional, cost-effective, and capable of securely housing strapping. Our customer who specialises in plastic extrusions was no different, they wanted to try a new solution to their reels – fast.

The Product: A polypropylene hand strapping reel, designed to hold and dispense strapping seamlessly while keeping it organised, tangle-free, and ready for use in securing packages and pallets.

The product was too bulky for our customer and they wanted to make it easy to handle and store.

As polypropylene degrades, it may release cadmium, a carcinogen that is toxic to plants and animals. This is often saw at the end of the product life cycle, when the plastic product is being broken down in landfills.

One of the main challenges is designing and manufacturing a reel design that is bespoke to our customer. (which means they will be able to assemble the product and store it efficiently.) The product must also be manufactured from a strong material in order for the product to be functional for the hand strappings.

The customers product in its current form is not flexible, with the option of assembly.

Second

The Solution:

We designed a strong, custom corrugated cardboard reel to replace plastic, we used CAD software for precision and a customer-focused functionality. Easy to assemble and store, it’s cost-effective and made from responsibly sourced cardboard material. The final product will be certified carbon-neutral allowing customers to report zero packaging emissions.

Selecting what material to use was the first challenge we tackled, we designed the customers new product; based on using our carbon neutral single wall corrugated material. This would be cost effective and assist our customer with their Sustainability goals.

We used modern technologies to design our customers new solution from scratch. Our experienced design team use CAD software to craft a sleek but yet functional design.

We opted for a die-cut design which allows the customers new packaging product to have a completely unique shape and design. (Sleek cut edges and custom shape)

The product is designed to be functional, and keeps all the customers wants and needs in mind. While also thinking about long term- use and goals.

Third

The Result & Testimonial :

A bespoke, functional and carbon neutral product that is inline with our customers goals. Designed and manufactured out of high quality 200KTBC corrugated sheet and ultimately a plastic-free alternative for our customers hand strapping reels.

As polypropylene degrades, it may release cadmium which is toxic to plants and animals. This is often saw at the end of the product life cycle, when the plastic product is being broken down in landfills.

Our solution is fully bespoke and keeps a customer – focused functionality. The customer now has the option to assemble their product in a matter of minutes, the product is easy to store and slightly fits their strappings better. Not to mention the whole of the corrugated reel is Carbon Neutral which assists our customer in their journey negating carbon emissions and becoming Net Zero.

The product is guaranteed to protect our customers hand strappings and provides a usable carbon neutral solution.

“We’re thrilled with our new reels! They work just like our old ones but are easier to store and far more cost-effective. The unique design is impressive, and we’re excited to explore adding printing for a personalised touch.”

— Plastic Extrusions Manufacturer

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