A new plastic handle for Emsafe pails: a smarter, fully recyclable design

We are proud to introduce our new plastic handle for Emsafe pails. The handle is the result of a project where we have replaced the traditional steel handle with a fully recyclable plastic version. The transition has brought together colleagues across Emballator and combined design exploration, technical problem solving and extensive testing. The result is a handle that is easier to produce, easier to use and easier to recycle.

Why a plastic handle?

Switching from steel to plastic gives us full control over the entire production process. It improves quality, reduces transport and storage needs and simplifies logistics. Most importantly, it makes the pail fully recyclable as a monomaterial product. This is something our customers value and it is also a clear requirement under PPWR.

Designing a handle that works

The design process began at our Innovation Center, where Brendon created thirteen different concepts focused on both form and function. From these, two variants were selected based on customer input and practical feasibility. We then 3D printed prototypes to test comfort, grip and stability in real use. After several refinement rounds, one design proved to be the right fit.

Turning design into production

With the design approved, our tool designer Stefan Nilsson adapted it for injection moulding. This involved fine tuning the geometry and adjusting material thickness to ensure the handle performs as intended. A key challenge was getting the handle to fall naturally into place and rest securely on the pail under its own weight. This detail is important for smooth assembly and daily use.

Testing, trials and collaboration

Once the test tool was ready, we ran trials using different materials and pail combinations. In parallel we worked closely with mould suppliers and assembly machine manufacturers to create a reliable and efficient process from the start. The project has been shaped by strong collaboration across teams and partners.

Looking ahead

The handle is only one part of a broader development effort. Work is also underway to introduce a new fully electric high precision injection moulding machine, update automation, refine the factory layout and improve storage and handling routines for the handles internally. These steps strengthen our ability to deliver reliable, high quality packaging solutions while reducing our environmental impact.

We look forward to continuing this work and developing products that support our customers’ needs today and in the future.