Helping Alliance Laundry Systems switch to paper-based packaging

By partnering with Smurfit Westrock, Alliance Laundry Systems replaced rigid foam plastic packaging (EPS) with a recyclable corrugated packaging, maintaining protection while reducing environmental impact, costs, and logistics complexity.

Alliance Laundry Systems is the world leader in professional washers and dryers, manufacturing machines built to operate continuously for up to 10 years in demanding environments such as hotels, hospitals and public laundromats. As part of its commitment to sustainability, the company set out to significantly reduce the environmental impact of its packaging without compromising protection or performance.

The Challenge

Alliance Laundry Systems relied on protective expanded polystyrene (EPS) components—corners, boards and prisms—to safeguard its machines during transport. While effective, the plastic packaging contributed to a high carbon footprint, increased waste and inefficient storage and transport, prompting the need for a easy recyclable, cost-effective alternative that could match the durability of EPS.

Industrial Washing Machine Packaging Fitments

The Approach

Smurfit Westrock replaced the EPS components with fully recyclable five-layer corrugated cardboard made with kraft paper. The solution was engineered with smart perforations to allow easy separation after unpacking, ensuring both robust protection and simple end-of-life recycling. The new design maintained the strength and durability required for heavy-duty machinery while optimizing storage and logistics efficiency.

The Result

The redesigned packaging eliminated 100% of the original EPS, saving 3.3 tons of plastic annually and reducing CO₂ emissions by up to 98%, equivalent to 15 tons per year. Packaging costs dropped by 26%, while storage and transport space requirements were reduced by 40%, resulting in fewer trucks on the road and fewer pallets in the warehouse. The packaging protects just as effectively as EPS, creates less waste after unpacking and can be recycled directly with paper waste—proving that sustainable packaging can deliver both environmental and economic value.

Winner at the 2026 WorldStar Awards

Products used by this client

Packaging Inserts

Our custom packaging inserts enhance the protection of items during transit and improve the presentation and unboxing experience for customers.

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Slip Sheet & Tier Sheet

Our slip sheets and tier sheets offer durable, recyclable, space-saving solutions, enhancing supply chain efficiency with customizable and protective paper-based designs.

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