A Samsung Galaxy Note 7 replacement model deemed safe by the company exploded on a Southwest Airlines flight in US just before take-off, causing emergency evacuation of passengers from the plane. Both Samsung and US consumer safety watchdog CPSC are currently investigating the matter.

"A customer reported smoke emitting from an electronic device. All customers and crew deplaned safely via the main cabin door," said a Southwest Airlines spokesperson.

Brian Green, owner of the Note 7 that exploded, told the Verge that he got the device from an AT&T store on September 21. The box of the phone shows a black square symbol, which Samsung uses to indicate a replacement Note 7.

Samsung issued a global recall of the Note 7, its newest flagship smartphone, after dozens exploded and caught fire worldwide due to a fault with their battery. Owners were told to stop using their phone immediately and return it; they have been offered a refund or a new, fixed Note 7 with the telltale black symbol on the box.

Meanwhile Samsung has said they are working with authorities to recover the device in question and confirm the cause of explosion.

The company said in a statement: "Until we are able to retrieve the device, we cannot confirm that this incident involves the new Note 7. We are working with the authorities and Southwest now to recover the device and confirm the cause. Once we have examined the device we will have more information to share."

Despite the replacement process kicking off for the Note 7 worldwide, many consumers have complained in the past week about the new device's battery still not functioning properly. Just recently in China a Note 7 user reported his phone caught fire despite the company claiming it was safe. In China though, a mass recall never took place as Samsung said the models there had batteries from a different manufacturer, ATL which are safe.

The latest incident will once again put the spotlight on Samsung, which has been trying to re-build its trust in core markets affected by the mammoth recall. Earlier US Federal Aviation Administration (FAA) had issued a warning saying Note 7 devices should be powered down and not charged while on planes or put in hold luggage.