One Insert Protects Four Laptop Sizes

Close The Loop repairs and redistributes HP laptops in four sizes: 10, 12, 14 and 16 inches. Protecting those devices required multiple packaging configurations and polyethylene foam inserts, adding complexity to inventory, storage and packing operations. The customer needed a solution that could accommodate every laptop size, protect both the device and charger during transportation, and reduce reliance on plastic materials.

We engineered an adaptable insert from recycled and recyclable corrugated board. Strategically placed die-cuts and fold lines allow the structure to adjust as it wraps around each laptop, holding the device securely while integrated air chambers absorb impacts. A dedicated air cell protects the charger within the same component. Supplied flat and assembled through folds and interlocking geometry, the insert replaces foam and adhesives with a mono-material, fiber-based design.

The corrugated insert delivered measurable operational, protective and sustainability benefits: 

• Consolidated four packaging configurations into one universal insert and standardized master carton. 
• Reduced SKU and inventory complexity while simplifying packing operations. 
• Improved storage and palletization efficiency while maintaining protection for laptops and chargers. 
• Eliminated polyethylene foam to create a fully fiber-based packaging system that can be recycled through established paper recovery streams without separating materials. 
• Received recognition at the 2026 Envase Estelar competition, organized by the Mexican Packaging Association (AMEE), in the electronics category.