Den Braven, a world-famous producer of sealants and glue and DS Smith Plastics co-designed one universal state-of-the-art briefcase to be used both for retail and E-commerce. DS Smith Plastics has the technique to produce packaging made from post-consumer plastic waste but Den Braven wanted to take this a step further and challenged the R&D department in Bilzen to produce the packaging of recycled empty tubes of seal and glue.
A new checkout concept, centring devices, R- flute® and specific mechanisation systems allowed DS Smith to create an innovative global solution.
The challenges were threefold: recoup the space lost to the mechanisation of the packaging boxes, maintain the vertical compression strength (BCT) and stability on pallets despite pre-cuts on the side of the boxes and finally, find a way to reduce the cost and size of the packaging.
We began by studying the mechanisation, palletisation, sales, etc. of existing cases in secondary packaging before selecting a “wrap-around” mechanised solution. The Shelf Ready Packaging (SRP) solution included a patented centring device, an R-flute® and a specific DS Smith machinery. The combination of these technologies helped to reduce the overall costs dramatically, with the bonus of being retail ready.
- Reduction in cardboard surface of 8%
- 50% less wrapping of pallets (857 kg of plastic films saved annually) thanks to 2 mm centring device on the top of each box and corresponding interlocking opening in the bottom of the next box up.
- 35% more cardboard banks per pallet* thanks to introduction of thinner R-flute® (2.2mm vs 3mm) cardboard
- Reduced number of trucks needed for delivery and subsequent reduction in CO2 emissions
- Efficiency of the new mechanization, increasing the packing productivity
*compared to B-flute
The SRP solution brings a number of additional benefits to the retail environment: it is easy to shelve thanks to its intuitive opening (removing the top panel and two forward lateral bands), it offers maximum visibility to consumers thanks to its recognizable base layer, and even in the event of reduced shelf height, the cases are easily reachable. The success of the DS Smith packaging solution was evident when it was awarded a Packaging Oscar in the corrugated materials category. More importantly though, is that the customer was happy enough with the solution to roll it out to other product lines within the group.
UK catering company Posh Nosh chooses expanded Polypropylene boxes to transport food
DS Smith Plastics, Foam Products worked with Posh Nosh Catering to strengthen their professional delivery image by supplying durable catering boxes which complimented their brand. The EPP foam boxes were selected for their excellent insulation properties that would keep catered food fresh during hours of transportation and also at the event itself.
Northampton Growers switch to Greencoat
Northampton Growers is one of the most respected produce companies in the United States, packing quality produce for distribution to grocery retailers, wholesale and terminal markets. With a goal of providing high-quality product in fresh condition to their customers, packaging that performs plays a key role in their success. From happy customers to cost savings, Northampton Growers has realized numerous benefits from their switch to Greencoat.
Tuoreboxi delivers sustainability, automation and better branding for Ab Chipsters Food Oy
Ab Chipsters Food Oy has a long history as a major player in Finnish fish processing. DS Smith's Tuoreboxi (Fresh Box) concept is a watertight, fibre-based, and recyclable packaging concept, which was successful in the New Wood 2017 competition in Finland, and a perfect fit for the Chipsters challenge replacing plastic-based solutions such as EPS boxes. The concept takes into account the whole packaging process, helps the company to achieve cost savings and improves environmental performance facilitating the company's everyday life.
Better Shelter is a social enterprise that develops and provides innovative housing solutions for the many people displaced by conflict and natural disasters. Through a groundbreaking collaboration with the UNHCR and the IKEA Foundation, Better Shelter started to develop ideas and designs for new shelter solutions.
With over 150 years of excellence Hardy Cognac has a history to celebrate and just the right product for celebration. But you cannot enjoy Cognac without just the right glass, so when Cognac Hardy approached DS Smith to create a unique packaging that included both a bottle and a glass we relished the opportunity.
At DS Smith we take pride in understanding the various sectors in which our customers operate. For example, the summer season is crucial for brewers, so in the spring our Danish sales team came up with an idea to help Royal Unibrew sell more beer at this key point in the year. Royal Unibrew loved the idea and the resulting displays drove sales in BILKA stores from mid-June.
Riese & Müller make exceptional e-bikes and need quality packaging to get their products safely and securely to market. Below is a condensed version of a recent article in VerpackungsRundschau about how DS Smith looked at their entire supply cycle to develop an entirely new packaging that’s better for protection, and better for customers.
- Elias Bittan
- Brand Launch
- Created 27 Oct 2015
- Modified 26 Nov 2015
- Hits 1777