Packaging solution replaces single use plastic for electronic display products

DS Smith and Raymarine, a manufacturer of navigation systems and electronics for the commercial marine and recreational boating sector, have collaborated to create an alternative solution to single use plastic in the company’s radar product line packaging.

In the new packaging, the DS Smith design team has used fibre based corrugated cardboard materials to replace Expanded Polyethylene (EPE foam) in Raymarine’s previous solution. This can ensure that the radar products are provided with a maximum protection against vibrations, unforeseeable physical impacts, and knocks, during their transit and transportation to local and international customers. 

The DS Smith designers have also incorporated a perpendicular shaped corrugated cardboard flute with a 90 degree angle into the packaging structure to provide built-in strength and a reinforced capacity to withstand shocks. Crumple zone layers were introduced to deform and absorb energy in the event of any collision, and installed fibre based air cushions to provide additional optimum support.

The overall structure of the packaging contains precisely shaped corrugated cardboard inserts to ensure that Raymarine’s Quantum radar products are held securely in place during any eventuality. The corrugated cardboard inserts are manufactured using a dedicated folding technique and within the design is an additional integral box to package product accessories and components separately.

The new packaging is designed for easy customisation and flexibility, and it can be made into a variety of different sizes. In addition, the innovation has successfully eliminated plastic, and significantly reduced CO2 emissions by over 60% a year in comparison to Raymarine’s previous packaging solutions. 

In terms of warehousing and distribution processes, the provision of corrugated cardboard inserts in flat packs has additional benefits for in-bound logistics – reducing the number of pallets required by 75% in comparison to previous packaging solutions where padding components were typically shipped as a single item. 

Levente Szabó, cluster director, DS Smith, Hungary, 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.’

DS Smith designers apply the Circular Design Metrics (CDM) approach when assessing packaging solutions, and this pioneering tool gives a clear identification of a packaging design’s sustainability performance and on where to focus attention. The CDM help to rate and compare the circularity of a packaging design across eight different indicators, ranging from recyclability, renewable content, and materials utilisation to carbon footprint and supply chain optimisation.

Andrew Smith, vice president, supply chain, Raymarine, said: ‘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. We have retained agility in our production process to accommodate varying order volumes, and we are proud of the packaging’s visual impact, which is clearly branded, instantly recognisable, and aligned with our core values.’