Sometimes the process of meeting a client’s needs seems nothing more than what we all do everyday, yet when we look back at each project we often realise that the end result brought forth a new product onto the marketplace. What did astronaut Neil Armstrong say? … “One small step for man …” Each new manufacturing step we take at The Container Connection (TCC) that modifies a product advances who we are and what we can achieve. This is the story of TCC NSW, our client – Qantas, and Andrew Berry of Berry Design. Together we moved the goal post and created a new playing field for the humble recycling bin.

In September 2009, Qantas Airways approached The Container Connection in Sydney enquiring if TCC had anything in the way of a recycling station that would be suitable for use in their terminals by the travelling public.

Qantas showed TCC a number of designs from overseas that they were considering, but none of them quite matched what they had mind. They wanted twin internal liners, one side to hold bottles/tins/cups and the other to take paper (particularly discarded newspapers). Originally the capacity was to be at least 60 litres per side.

Recycling stations in terminals are not new, of course, but Qantas was keen to have something that had some style and would look good in their departure and arrival halls. They were also particular about the size and shape of the openings and cost was an issue. Stainless steel recycling stations can range from $1,500 upwards and we needed to do better than that.

The Container Connection recently supplied Monash University with a large number of recycling stations but these did not suit The Qantas situation. This meant TCC would have to start from scratch.

We met with the Qantas team comprising people from Airport Customer Delivery, Airport Services, Ground Safety & Environment, and Compliance. Surprisingly, despite the number of views represented at this round table meeting, it was not difficult to find consensus on the major issues.

In view of the relatively short production run, the first design was for a fibreglass body with twin liners. Tooling is comparatively cheap and one of the many things The Container Connection is great at is creating attractive finishes. Qantas became interested, particularly when we exceeded the target capacity and kept the dimensions to only 740 long x 750 high. The removable lid would have two holes to meet the client’s preferred bin shape.

It soon became obvious, however, that the potential market for good looking, functional and relatively inexpensive recycle bins, in the right material, is bigger than one short run for a single client. There really is not much like this being made in Australia and, therefore, TCC could justify offering the bin in a better material - rotor moulded polyethylene. Tooling is more expensive, but the product is superior in many ways.

Indeed, we could now say to Qantas that not only is this recycle station made in Australia, it is also made from a material which is rated by ‘ecospecifier’ as a green product; and, its use can contribute points towards a green star rating. It is fully recyclable and emits almost zero VOCs (volatile organic compounds), making it a healthy material in indoor spaces. It is also extraordinarily tough and long lasting. Even after years in the sun it will not fade or go brittle and crack. This project was really taking shape and it had the feel good factor.

We then moved to design details. The bin lid was to have two large holes approx 300mm in diameter and fixed underneath we added metal discs. These discs could meet whatever hole size and shape the client wants. Qantas wanted a circular hole for the glass/tin/cups and a 40-50mm slot for newspapers, thus requiring some attempt to fold the papers before dumping. The weight of the lid became a OH & S issue so we designed a hinge into it, and also a lock was required to be keyed like the other cabinets and boxes the terminal staff use. At this point, the project was handed to Andrew Berry of Berry Design to add some style and to modify, where necessary, to ensure this new recycle bin was capable of becoming a rotor moulded product.

Andrew’s design transformed the bin as he added curves and sweeping lines turning this already planet friendly recycle bin also into a very attractive piece. We were very excited and enthusiastic with how this new product was shaping up.

However, with some processes it is one step forward and then one step back and so it was with this process. A new challenge arose when Qantas became concerned that the lid, as beautiful as it was with its bowl shaped sweep, would trap dirt or fluids. Andrew Berry went back to work and his second design version resolved this issue.

After completing a product safety and risk analysis the design was approved and the tooling is now under construction.

Here at The Container Connection (NSW), we expect to deliver the first, Australian made, rotor moulded polyethylene recycle stations to Qantas within a couple of months. Qantas will be unveiling them in their Sydney, Melbourne, Brisbane and Perth terminals not only as a functional item, but as an attractive addition to their departure and arrival halls.

At the time of writing, Qantas is still deciding on the words and graphics that will be fixed to the front and lid of their new recycling bins.

The end product came a long way from the “recycle twin bins” produced originally for Monash University, through that initial sketch phase, to Andrew Berry’s very smart final design. Stay tuned.