Structural Design Solutions Resolving Packaging Challenges — Case Study: Enhancing Customer Product Packaging

Molded pulp packaging shows promise in eco-friendliness but may not be ideal for specific products.In this case, our client, a young, brand-conscious enterprise specializing in high-value customized laptops, sought sustainability and requested molded pulp packaging to align with their values. We successfully utilized molded pulp for packaging, achieving ISTA 2A certification for production and shipping.

Unexpected Setback: Customer Complaints on Molded Pulp Packaging

Following shipment, the client reported consumer complaints regarding the delamination of molded pulp trays, jeopardizing product integrity. This issue came as a surprise to us, as we believe that the primary function of packaging is to protect the product. All our packaging undergoes ISTA 2A laboratory testing to ensure quality before mass production begins. Further investigation revealed that variations in transportation environments across different countries led to unexpected issues.

Critical Packaging Concerns Urgently Addressed

Due to molded pulp’s limited protection, reliance on plastic cushioning materials like EPE foam became necessary, posing recycling challenges and space constraints.

We identified the following pivotal issues that needed to be tackled:

1. High delamination rate of molded pulp trays leading to insufficient protection.
2. Adhesive overflow affecting packaging aesthetics.
3. EPE foam occupying space, difficult to recycle, environmentally unfriendly, and impacting transportation efficiency.

Proposed Packaging Optimization with All-Paper Structure

We proposed an all-paper structure solution to address concerns, replacing molded pulp trays with glue-free paper structures. This enhanced structural integrity, passed a 91cm drop test, and presented the following benefits:

• Sturdy construction ensuring double protection and passing drop tests.
• Elimination of glue overflow.
• Aesthetic appeal suitable for direct retail tray transportation, reducing EPE foam usage and environmental impact.

Enhancing Transportation Efficiency, Reducing Carbon Emissions

Optimization improved structural stability and product protection, reduced EPE foam usage, enhanced transportation efficiency, and reduced carbon emissions.

• The volume of transportation materials reduced by 22%!
• The number of pallet stacks increased by 20%. Based on a standard pallet (1200x1000mm) calculation, 12 more boxes can be loaded!
• The transportation volume increased by 20%. Based on an 8-ton capacity truck calculation, each trip can carry 96 more boxes!

Embracing Recyclability and Sustainability

The glue-free, recyclable, all-paper design significantly enhances packaging sustainability. Although manual shaping increases labor costs, the advantages outweigh the drawbacks. Following successful sample production and testing, three months of the mass output have passed without consumer complaints, affirming the solution’s efficacy in real-world transit scenarios.

Power for the Possible! We are Fudy, your product packaging consultant.