Sensitive automotive components place high demands on packaging technology, as every surface must remain flawless and component geometries allow for little error. Antalis has now developed an innovative solution that eliminates the need for foam and relies on fibre-based materials. This solution protects components just as reliably as established plastic cushioning, but is more resource-efficient and simplifies the packing process at the line.
For an automotive manufacturer, Antalis' Packaging Design Centre sought a way to safely package extremely scratch-sensitive trim strips for overseas shipping without using foam. At the heart of the development is a system of four precisely engineered moulded fibre pads that accommodate the contours of the trim strips with millimetre accuracy. Two mirror-image variants allow for the secure positioning of both left and right components.
Precision through digital and physical prototypes
The design of the folding technique and the fit of the pads were optimised through the use of 3D-printed prototypes. This method allowed the shape to be realistically tested and the protective effect to be ensured within two weeks. „This process was crucial for the entire concept, as any deviation in geometry would have had an immediate impact on the protective effect,“ explains Heike Rauh, packaging engineer at Antalis Packaging.
The system proved itself in practice not only through its functionality but also by simplifying the packing process. The defined positioning of the pads facilitates handling, and the construction allows for simpler and faster assembly. The required packing density of six components per layer and four layers per container is maintained, demonstrating that fibre moulding solutions do not entail loss of space or increased handling effort.
Environmental compatibility as an integral part
The new concept is also convincing in terms of resource conservation. The complete replacement of the foam solution with moulded fibre, corrugated board, and chocolate wrapper paper creates a material-homogeneous packaging that can be fed into paper recycling. This environmentally friendly solution offers both ecological and practical advantages and meets the mechanical stability requirements in an industrial environment.
The results of the project show that fibre-based packaging solutions can offer significant potential for complex component geometries. They improve product protection and meet key environmental requirements. „For us, this project clearly demonstrates that fibre-based solutions can play a key role in automotive packaging design – and beyond – in the future,“ says Kai Hofmann, Head of the Packaging Design Centre at Antalis Packaging.
Source: Antalis packaging
