Up until now, Trunki products sold in the UK and Europe have been made in China. But, by re-engineering the product, the company will be able to manufacture Trunkis in the UK for the first time. And plastics play a crucial role in this.
"We've gone back to the drawing board to design all the metal out of the product," says Truncki inventor and Magmatic founder Rob Law, one of a handful of product designers with an MBE for services to design.
"The new version will snap-fit together, making it cost-effective to assemble here," he adds.
One example is the 'horns' that the child holds onto when astride the Trunki: these are currently attached to the body of the case with three screws, but this has been re-designed into a 'non-return' snap fit.
In all, the redesign eliminated 25 metal components, and all adhesives.
The case's locking mechanism was a real challenge, but the original metal version has been replaced with acetal; acetal and PP are the only two materials used in the new product, which simplifies end-of-life recycling.
Magmatic began tooling for the re-designed products in September 2011 and was due to start production – in Devon – in April. Production will start with a number of Olympic-themed lines, including 'Team GB' and 'London 2012' versions. Later, Magmatic plans to roll out all the usual Trunki designs too.
Components will be injection moulded by Inject Plastics, based in Totnes. The company is moving to larger premises so that it can also carry out the assembly. By the end of 2012, Law wants all UK-sold Trunkis to be made here.
While the tooling cost will be six times higher – tools are now made in Manchester, rather than China – lead times are a fraction of what they were.
This will shrink product delivery time from 120 days to 30 days, says Law, meaning that the product is effectively 'never out of stock'.
Re-engineering was the main factor allowing production to come to the UK, but a weak sterling and the high cost of shipping have also played their part. Material cost is immaterial, as he says it is "the same the world over".
The main material used for the product is a polypropylene (PP) co-polymer, which is tough enough to withstand the battering it gets - as well as the weight of its passenger.
"By using intelligent design and engineering you can make products more cost-effectively in the UK," Law says.
