Product development process of plastic handles for Emsafe pails

Posted 2025-05-27

We are proud to present our latest innovation: plastic handles for our Emsafe pails. This project has been a journey filled with challenges and successes. Robin Hallqvist, Product Manager, shares the process and the benefits of the new plastic handle.

 

Advantages of plastic handles

By switching from steel to plastic, we have gained full control over the production of the handles, ensuring high quality. Additionally, it reduces transportation and storage needs. The biggest advantage of the plastic handle is that it contributes to the ability to recycle the bucket in its entirety. This aligns with the requirements we have from our customers and PPWR, regarding monomaterial in packaging.

 

Design process

The design of the new plastic handle has been a challenging but rewarding task. We started by seeking help from our Innovation Center, where Brandon, our designer, created 13 different design variants focusing on a stylish and functional design. After selecting two variants based on customer preferences and processability, we 3D-printed them to test the feel and stability. After several rounds of adjustments, we finally settled on one.

 

Technical development

Stefan Nilsson, our tool designer, took over and adapted the design for injection molding. This included adding and removing material in various places to ensure the handle functions as intended. One of the biggest challenges was ensuring that the handle falls freely down and rests on the bucket by its own weight when released, which is important both during assembly and separation.

 

Testing and collaboration

When we were satisfied with the design, a test tool was manufactured. We ran trials and tested the handle with different materials and on various pails. At the same time, we engaged in dialogue with the manufacturers of the molds and assembly machines to ensure a safe and efficient process.

 

Future challenges

Beyond the handle itself, there are several other aspects of the project we are working on, including a new fully electric high-precision injection molding machine, automation, factory layout, storage of the handles, and safe handling of the handle mats internally. We are very enthusiastic about continuing to develop our products to meet our customers’ needs and requirements, while reducing our environmental impact.

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