International Paper company DS Smith has partnered with navigation systems manufacturer Raymarine to develop new packaging for Raymarine’s radar products that eliminates single-use plastic.
DS Smith replaced expanded polyethylene (EPE) foam with corrugated cardboard made from fibre.
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The company said that this change maintains protection for the radar products during shipping by guarding against vibration and physical impacts.
The packaging design includes a perpendicular corrugated cardboard flute at a 90° angle to add strength and absorb shocks.
Layers intended to act as “crumple” zones have also been introduced, along with air cushions made from fibre-based material for extra support.
DS Smith Hungary cluster director Levente Szabó said: “We are dedicated to helping our customers in finding new solutions for sustainable and circular-ready packaging. When assessing a new packaging design, our process and development research consider the type of materials used, production, transportation, distribution, and supply chain optimisation.
“This packaging for Raymarine is made from 84% recycled content versus 40% in previous packaging, and it is 100% recyclable at end of life. We have successfully replaced EPE, and we can support manufacturers in both consumer and industrial sectors.”
Cardboard inserts shaped specifically for the product are used to keep the radar units secure during transport. The inserts use a folding technique, and the packaging includes a separate box for accessories and components.
The design allows for customisation to different sizes.
According to DS Smith, the switch to fibre-based packaging has removed plastic from this product line’s packaging and reduced annual carbon dioxide emissions by more than 60% compared to previous methods.
Raymarine supply chain vice-president Andrew Smith commented: “One of our objectives is to eliminate single-use plastics from our packaging, and thanks to our collaboration with DS Smith, we are making positive progress towards that goal.
“The new packaging ensures that products from our radar range are well-protected during transit while also meeting the demands of diverse climatic conditions and long-haul international shipping.”
DS Smith assessed the new packaging using its Circular Design Metrics tool, which evaluates the sustainability of packaging solutions.
