Client Brief
Twinplast’s capabilities in custom design and manufacturing measured up to the exacting requirements of a major airline, giving flight to their ambition to create a branded baggage sizer. British Airways required the application to be used in airports to help passengers determine whether their hand luggage met the airline’s dimensional restrictions. The project called for a durable, lightweight, and precisely manufactured product that would maintain structural integrity despite frequent handling in high-traffic areas. Twinplast was selected for this bespoke project due to our expertise in corrugated polypropylene solutions.
The Solution
Twinplast collaborated closely with British Airways to develop a baggage sizer that met exacting dimensional requirements. Given that even minor discrepancies could affect compliance with airline regulations, precision was paramount. Twinplast’s design team utilised advanced modelling to ensure accurate dimensions before moving into the prototyping phase. Corrugated polypropylene was an ideal material due to its excellent strength-to-weight ratio. Unlike traditional materials such as metal or rigid plastics, corrugated polypropylene offers a combination of robustness and flexibility, making it ideal for high-traffic airport environments. Its lightweight attributes and built-in carry handles enabled easy handling for airline staff and customers.
The baggage sizers needed to withstand continuous use, including handling by passengers and airport staff. Corrugated polypropylene provided the perfect balance of rigidity and impact resistance, ensuring longevity in demanding settings. Additionally, the material’s water resistance and ease of cleaning further contributed to the product’s durability, maintaining a professional appearance over time.
Bespoke Printing & Branding
One of the key aspects of the project was ensuring the baggage sizers aligned with British Airways’ brand identity. Twinplast leveraged its in-house bespoke printing capabilities to apply high-quality, durable branding directly onto the polypropylene surface. This allowed for vibrant, long-lasting print that was resistant to fading and wear, ensuring the airline’s messaging remained clear and professional.
Sustainability & Recyclability
In addition to its durability, corrugated polypropylene is 100% recyclable. At the end of its lifespan, each baggage sizer can be fully recycled, minimising environmental impact. Twinplast’s commitment to eco-conscious manufacturing ensured that sustainability was embedded into every stage of the product’s lifecycle.
Twinplast successfully delivered a fleet of precision-manufactured baggage sizers that met the airline’s strict specifications. The final product provided passengers with an easy-to-use tool for checking their baggage dimensions while reinforcing the airline’s commitment to efficiency, brand consistency, and sustainability.
Through expert design, custom manufacturing, and high-quality branding, Twinplast demonstrated our ability to produce bespoke solutions that are both functional and environmentally responsible.
For more information on how Twinplast can develop custom solutions for your needs, contact our technical team on 01582 361720 or sales@twinplast.co.uk.