Developing protective packaging for solar panels

How we helped Priwatt speed up the packing of its solar panels and reduce damage rates.

Priwatt, a pioneering German clean energy company, faced inefficiencies and packaging-related waste in the distribution of its plug-and-play solar systems. Its previous packaging approach relied on bulky adhesives and tape, leaving panels vulnerable to damage and slowing the packing process. By switching to a smart, tape-free packaging design with a secure snap-in fit, the company significantly reduced damage rates and increased daily output. The solution also earned the 2024 German Packaging Award for cost-effectiveness.

THE CHALLENGE

German-founded Priwatt is dedicated to building a sustainable future by offering easy-to-use, plug-in solar systems that allow anyone to generate their own green energy. The company sought better packaging solutions to distribute solar panels more efficiently—reducing damage, eliminating adhesive tape and speeding up the packing process.

THE APPROACH

The design team analyzed Priwatt’s existing solution and made two key changes to significantly improve its packaging. They developed separate base and lid sections using different flute types to provide the precise level of protection needed. A snap-in mechanism was also introduced during assembly to secure the contents during transit, eliminating the need for adhesive tape.

THE RESULT

Priwatt’s new packaging has streamlined operations by eliminating the need for adhesive tape and cutting assembly time in half. What once required two employees now only needs one— reducing labor needs and increasing efficiency. As a result, daily output jumped from 250 to 800 packages, while the damage rate dropped to just 1%. The new solution was also recognized at the 2024 German Packaging Awards, where it won in the cost-effectiveness category.

“A fantastic and sustainable result that was an important milestone for scaling our logistics processes”

Kay Theuer, Managing Director at Priwatt.