Replacement of non-recylable materials for ecommerce solutions

The customer manufactures an alternative to regular Wi-Fi routers. Due to the value and fragility of the product, the customer ships these out in an outer case with a bespoke foam fitment, however the fitment is made from non-recycled materials and costs the customer £16 per pack. The challenge from the customer was to provide a recyclable alternative that would still protect the product in transit, but at a reduced cost.

The design is made using E flute and folds up into sections that mimics the current foam fitment layout, while still holding all parts securely in place. An added benefit is that when assembled, the fitment can be left freestanding and doesn’t require to be packed within the 0427 outer to retain its desired shape.

This development is our first opportunity with this customer. The 0427 outer is digitally printed on both sides using E flute with a 180gsm coated outer and 115gm white kraft inner, where instructions are accessed via a QR code printed on the inside of the lid. The bespoke fitment is unprinted using E flute with a 135gsm white kraft paper on both the inner and outer sides of the board.

The pack achieves the objective by retaining the same level of transit protection, while being fully recyclable and significantly cheaper.

Volume quotation is in 50 & 100 lots per delivery (no annual usage prediction has been supplied), The outer box and the fitting have solved a significant challenge for the customer and also saved between 40% and 70% on other material costs depending upon batch quantity. Boxes are delivered flat on a pallet for the customer to self-assemble. No other packaging besides the 0427 outer and bespoke fitment inner is required.