Overview
‍With increasing demand for sustainable practices, we led the transition from plastic packaging to eco-friendly solutions for products shipped globally, including destinations as far as America, Africa, and Australia. The challenge was to match the impact resistance traditionally provided by plastic while using more environmentally friendly cardboard alternatives. We carefully engineered new structural solutions in collaboration with suppliers, successfully maintaining the same level of strength and protection. Complex folds, bends, and tabs eliminated the need for expanded polymers, while bespoke cradles prevented surface damage during transit. The final design was a robust, eco-conscious packaging solution ready for international shipping.

‍Methodology
‍We collaborated closely with material experts and suppliers to eliminate plastic and develop innovative cardboard packaging. Using precise “cardboard engineering,” we were able to maintain the same level of impact resistance. By utilizing strategic folds, bends, and tabs, we created secure enclosures without the need for void fillers. To prevent damage from cardboard edges, we created custom cradles that protected product surfaces. We also optimised packaging density and modularity, reducing material use and shipping costs. Our redesign combined functionality, sustainability and cost-effectiveness, all while ensuring a minimal carbon footprint throughout the packaging’s lifecycle. 

‍Results Discussion
‍Our shift to plastic-free packaging met strict environmental standards and addressed the growing demand for sustainable solutions. By replacing single-use plastics with cardboard alternatives, we created a packaging system that was both environmentally responsible and operationally efficient. Overall, our redesign delivered structural integrity and product protection, met sustainability goals, and generated cost savings, providing a replicable, eco-conscious solution for international markets.