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.

Bulky - Hassle to store and can be heavy

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

Non Environmentally Friendly

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

Bespoke Nature: Tailoring it to our customers needs

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.

Usability

The customer’s 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, using CAD software for precision and customer-focused functionality. Easy to assemble and store, it’s cost-effective and made from responsibly sourced cardboard material.

Material Selection

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

Unique CAD Design

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

Die-cut Packaging

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

Functionality

The product is designed to be functional, and keeps all of the customer’s wants and needs in mind while incorporating long term use and goals.

Third

The Result & Testimonial :

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