DS Smith has entered into a new partnership with automotive components supplier TPV Automotive to develop an eco-friendly, plastic-free packaging solution for Bayerische Motoren Werke’s (BMW) car wheel carriers.
The design teams at DS Smith focused on creating packaging using fibre-based corrugated cardboard that conformed to the intricate 3D shape of the wheel carriers.
The primary goal was to ensure the parts were protected during shipping, preventing any movement that could result in damage.
The new packaging design is expected to ensure the safe and efficient transportation of automotive components.
Each wheel carrier weighs approximately 8kg, with 20 units per pallet.
The packaging is engineered to hold up to 160kg per pallet, providing stability and security during transit.
Additionally, the packaging is compact enough to fit into cargo containers for shipment to BMW’s assembly plant in Asia.
Three-dimensional corrugated cardboard inserts are tailored to snugly fit into the base of the packaging. This design ensures that the car wheel carriers are firmly anchored within the designated compact spaces.
TPV Automotive receives these inserts as flat cardboard sheets designed to be folded in an accordion fashion to create the exact 3D shape needed for the auto-part placement.
The complete packaging solution includes a cardboard pallet box, base inserts for the packs, and a flat cardboard panel that serves to reinforce the top of the package once the components are put together.
DS Smith subregional SMI director Jožica Hojnik said: “Our designers had to think outside of the box quite literally to develop an entirely new and unique packaging solution for TPV Automotive.
“Our new packaging solution is designed to provide maximum protection for heavy automotive components during cargo while using sustainable and durable materials.
“This is a particularly unique innovation due to the accordion-style folding system of the 3D inserts and dimensional flexibility.”
Earlier this month, DS Smith launched a recyclable and reusable cooler.
