Replacing foam with paper-based, protective packaging

Helping Danfoss switch to paper-based packaging, eliminating 300 tonnes of plastic per annum

Danfoss, a manufacturer of AC drives for electric motors, faced environmental and logistical concerns from using expanded polystyrene (EPS) foam in its packaging. The company switched to a 100% paper-based solution with a corrugated box and custom honeycomb insert, tested in an ISTA-certified lab. The change improves product protection in transit and supports Danfoss’ goal of carbon neutrality by 2030.

Hear directly from our customer Danfoss on its experience of switching from Expanded Polystyrene (EPS) to paper-based packaging which is renewable and recyclable.

The Challenge

Danfoss, a manufacturer of AC drives for electric motors, was looking for an eco-friendlier solution to pack its VLT® drives. They previously used EPS foam, which is not biodegradable and in some parts of the world it ships to, its customers don’t have the infrastructure to recycle, which was causing environmental concerns.

The Approach

Our experienced team designed a 100% paper-based solution, comprising of a corrugated box with a bespoke hexacomb fitment, to secure the VLT® drive and its accessories whilst in transit. We then performed pre-shipment tests in our ISTA certified laboratory to ensure this new sustainable solution would confidently withstand the rigours of the supply chain.

The Result

With this new, sustainable and easy-to-recycle solution, Danfoss anticipates it will remove 300 tonnes of plastic from its supply chain each year, and contribute towards Danfoss’ target of being carbon neutral by 2030. Having passed ISTA testing, they can ensure a safe delivery of its products whilst meeting the sustainable packaging demands of its customers.

Products used by this client

Corrugated Boxes

Strong yet lightweight corrugated packaging boxes, customized to your product.

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Honeycomb Packaging & Honeycomb Sheets

Our honeycomb sheets are ideal for creating durable yet lightweight packaging solutions, effective signage, and versatile displays across various industries.

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