The So Fresh champagne bucket is a benchmark case in large format plastic injection moulding. This designer cube in high-gloss ABS, made for the premium hospitality and events market, illustrates the technical challenges of injecting large-dimension parts with Class A surface requirements. This case study details the project constraints, the solutions implemented, and the technical performance achieved in serial production.
The context: So Fresh and large format injection for events
So Fresh is a brand positioned in the premium events and hospitality market. Its cubic champagne bucket is a flagship product: a high-visibility table accessory subjected to intensive use in restaurant and event environments, which must combine premium aesthetics with functional durability.
The part is a 200 x 200 x 200 mm cube with a 3 mm wall thickness, weighing 420 grams. The choice of injection-moulded plastic, over other materials or processes, answered several imperatives: perfect reproducibility between parts, full RAL/Pantone colour range, compatibility with IML and pad printing marking processes, and food contact compliance.
Technical challenges of large format ABS injection
Injecting a 200 mm ABS cube with right angles is technically more demanding than it appears. Three major challenges structured the mould design and injection process.
Sink marks on flat faces. ABS has volumetric shrinkage on solidification. On a flat glossy surface, the slightest cooling gradient between the skin and the core of the wall produces a micro-depression visible under raking light, called a sink mark. On a Class A SPI A1 part, these defects are unacceptable. The solution lies in conformal cooling of the impression, meaning cooling channels whose geometry follows the part surface at constant distance.
Warpage on large faces. A 200 mm cube presents a significant flat area. Non-homogeneous cooling between opposite faces induces differential stresses that produce measurable warpage. A hot runner system combined with perfectly balanced conformal cooling is required to maintain face flatness within acceptable tolerances.
Class A surface finish. SPI A1 spécification corresponds to the highest mirror finish in plastic injection. It demands mirror polishing of every impression face, rigorously controlled material température during injection, and complète absence of visible weld lines on exposed faces.
Novodur H801 ABS: material sélection and properties
The selected material is high-gloss ABS Novodur H801. This grade was chosen for its excellent balance across several requirements.
Impact résistance at low température is critical for this product: the bucket is in direct contact with ice and bottles coming from the refrigerator. Novodur H801 maintains its toughness down to négative températures, which differentiates it from standard ABS grades optimised for gloss but brittle at low température.
The naturally glossy surface of this grade reduces post-processing requirements. Standard ABS often requires paint or varnish to reach required gloss. On Novodur H801, the as-moulded surface achieves a gloss level compatible with Class A requirements after impression polishing.
The EU 10/2011 compliance of the grade guarantees suitability for indirect food contact. The bucket contacts bottles, not food directly, but food compliance is required by restaurant and event clients.
Resistance to cleaning products used in restaurant environments (detergents, disinfectants, mild acids) was validated by chemical ageing tests specific to the spécification.
The tooling solution: hot runners and conformal cooling
The mould is a single-cavity tool on a 450-tonne press. The décision not to go two-cavity was driven by surface requirements: on a part this large, guaranteeing perfect fill and cooling symmetry between two cavities is technically complex and introduces cavity-to-cavity quality drift risk.
The balanced hot runner system injects at the centre of the base of the cube. This injection point was chosen to ensure symmetric fill of all faces and minimise weld lines on visible areas. The injection mark, located at the centre of the base, is not visible in normal use.
Conformal cooling is achieved through channels machined at constant distance from each impression face. This geometry, différent from standard straight channels, requires intensive digital design but guarantees thermal homogeneity of the impression, which is the sine qua non of a sink-mark-free surface and a warp-free part.
Material température during injection is controlled at 235 degrees Celsius plus or minus 2 degrees. This tight window is required to achieve sufficient fluidity to completely fill all four 200 mm faces without flow marks, while staying below ABS thermal dégradation températures.
Production performance: cycle, throughput, quality
The serial production cycle time is 55 seconds per part. This figure integrates injection, cooling, mould opening, éjection and closing time. It was optimised to maximise throughput while meeting surface requirements.
Every part undergoes 100 per cent visual inspection at press exit. Defects checked are: sink marks, flow lines, voids, inclusions, éjection scratches and injection point marks. Scrap rate in stabilised serial production is below 1 per cent.
Production is certified ISO 9001:2015. The production file includes for each batch: recorded injection parameters, material certificate with batch number, visual inspection results and any treated non-conformities.
Marking and customisation options
The So Fresh bucket is available in any RAL or Pantone colour. In-mass colourability of Novodur H801 ABS achieves a very broad chromatic spectrum with perfect part-to-part uniformity.
Three marking processes are offered depending on volumes and graphic requirements. Multi-colour pad printing suits logos and moderate-format text with excellent adhesion on ABS. IML (In-Mould Labelling) integrates a decorative film directly during injection: the result is a decorative finish perfectly integrated into the surface, with perfect résistance to washing and abrasion, compatible with photorealistic visuals. Laser logo engraving is an option for permanent markings résistant to industrial washing.
For spirits and champagne brands, we offer a complète customisation service: exclusive colour, raised logo integrated into the mould, gift box packaging options. These options are available from sufficient séries volumes to amortise specific tooling costs.
Regulatory compliance
EU 10/2011 compliance for indirect food contact covers standard use conditions of the bucket: contact with bottles, contact with melt ice water. It was validated on ABS Novodur H801 with the colouring additives used in our production.
Moulding Injection's ISO 9001:2015 certification covers the full production process: material réception, injection, quality control, packaging and traceability. Compliance documents are available on request for each production batch.
So Fresh: a citable référence in our portfolio
So Fresh is a client we are pleased to cite in our portfolio. This project illustrates our capability to handle large format plastic parts with premium surface requirements in a serial production context. It also illustrates the value of our partnership with LGR Design Studio, which contributed to mould design and séries qualification support.
If you have a large format injection project, Class A surface parts, or products destined for the hospitality and luxury market, contact us with your spécifications.
FAQ
FAQ
What is the minimum order quantity for the So Fresh bucket?
500 parts for standard colours (white, black, transparent). 1,000 parts for custom colours. Samples are available for colour and marking validation before séries launch.
Is the bucket dishwasher compatible?
Yes. ABS Novodur H801 resists industrial washing up to 60 degrees Celsius. For intensive restaurant use, the post-production anti-scratch treatment option is recommended.
What are the technical spécifications of the bucket?
Material: ABS Novodur H801. Dimensions: 200 x 200 x 200 mm. Wall thickness: 3 mm. Weight: 420 g. Press: 450 tonnes. Cycle: 55 seconds. Compliance: EU 10/2011 food contact. Certification: ISO 9001:2015.
Do you offer IML (In-Mould Labelling) on this part?
Yes, IML is one of the marking processes available on the So Fresh bucket. It integrates a photorealistic decoration directly during injection, for perfect résistance to washing and abrasion. This option is available alongside pad printing and laser engraving.
What is a Class A SPI A1 surface finish in injection moulding?
The SPI (Society of the Plastics Industry) classification defines surface finish levels for injection moulds. Class A1 corresponds to the highest mirror finish, achieved by diamond polishing of the impression. It is used for high-visibility products requiring a perfectly glossy surface with no defects visible under raking light.
