Case Study: Wray Cup

10-04-2025

CLIENT NAME: harr + bass

PROJECT: Wray Cup

QUANTITY PRODUCED: 10,000 units

What Inspired Your Project?

We had been producing paper cups for our client, Wray & Nephew, which had become iconic with their brand. However, after manufacturing 200,000 paper cups last year, the demand for a reusable alternative emerged. The on-trade sector expressed interest in a product that not only had longevity but also preserved the familiar appearance of the now-iconic Wray & Nephew paper cup. This inspired us to embark on creating a sustainable solution that upheld brand identity while addressing environmental concerns.

What Challenges Did You Face?

Design Complexity: Replicating the intricate details of the paper cup posed a significant challenge. Standard product designs couldn’t capture the essence of the original, requiring a fully bespoke product to meet expectations.
Sustainability Requirements: Transitioning to a reusable cup with superior sustainability credentials while ensuring it remained premium and cost-effective proved difficult. Although we considered bamboo, it became evident that bamboo products often lack the sustainability they’re reputed for.
Printing Specifications: The original paper cup featured a print design that covered much of the surface and incorporated a deliberately worn appearance as part of the brand’s image. Replicating this unique design on a durable material was a complex task.

How Did GCP Help Overcome Your Challenges?

Great Central Plastics (GCP), renowned for their expertise as sustainable injection moulders, proved instrumental in overcoming these challenges. Here’s how they supported us:

Precision Design and Tooling: Leveraging GCP’s in-house toolmaking capabilities, they perfectly reverse-engineered the paper cup to create an injection moulding tool tailored to replicate the intricate design. This bespoke solution ensured that the product not only met but exceeded expectations, while remaining viable for large-scale production. As leading UK Toolmakers, GCP’s technical expertise ensured the Wray Cup was designed for efficient and sustainable manufacturing.
Material Selection: GCP’s extensive experience as plastic injection moulders and their access to a wide range of eco-friendly materials streamlined the material selection process. The chosen material, a combination of LIMEX and BDP supplied by LXD, offered exceptional sustainability. This unique blend is biodegradable, ensuring the product’s eco-credentials align with the brand’s commitment to reducing environmental impact. LIMEX not only enhanced the Wray Cup’s sustainable properties but also provided a premium feel at a competitive cost, elevating the product’s market appeal.
Collaborative Printing Solutions: GCP’s ability to collaborate closely with stakeholders facilitated the reproduction of the distinctive print design. Their technical acumen ensured that the worn appearance and branding were flawlessly transferred onto the durable material, preserving the iconic look of the original paper cup.

The Final Product

The result was a high-quality, eco-friendly reusable cup that maintained the aesthetic and functionality of the original paper version. By partnering with Great Central Plastics, Harr + Bass successfully delivered a product that exceeded client expectations while advancing sustainability goals. The Wray Cup exemplifies how plastic manufacturers, particularly sustainable injection moulders, can transform brand vision into a tangible, environmentally responsible product.

This project underscores the importance of collaboration and innovation within the plastic manufacturing industry to meet modern sustainability demands. Thanks to the expertise of GCP as leaders in eco-friendly injection moulding, the Wray Cup is a testament to the future of sustainable product design.

For more information on Case Study: Wray Cup talk to Great Central Plastics Ltd