Nextpack has developed a paper-based packaging solution for a manufacturer of washing machines that completely replaces polystyrene and at the same time fulfils the high requirements for product protection, production and logistics.
Washing machines are among the more logistically demanding products. High weight, delicate edges and specific handling in the supply chain often lead to transport damage with high consequential costs. Until now, Styrofoam has mainly been used for this purpose - functionally proven, but increasingly critical from an ecological and regulatory perspective.
The aim of the project was to develop a sustainable alternative that could be seamlessly integrated into existing production and logistics processes while offering the same level of protection. The new solution is designed in such a way that it can be used in the packaging process without any adjustments and is functionally equivalent to the existing polystyrene.
Stable honeycomb elements are now used, which are specifically positioned in areas subject to stress. Highly compacted edge protection elements, a flat load distribution and the fixing of the appliance without additional plastic or polystyrene elements ensure safe transport. The design utilises the high compressive strength of honeycomb cardboard. While polystyrene can withstand loads of around 6 tonnes/m², honeycomb cardboard achieves compressive strengths of up to 30 tonnes/m², depending on the design.
Sustainable and suitable for production
In addition to product protection, the new packaging solution fulfils key requirements for recyclability and material reduction. The paper-based design can be fully integrated into existing recycling streams and is orientated towards the upcoming requirements of the EU packaging regulation (PPWR).
Source: Nextpack
