DS Smith has partnered with Schneider Electric to develop a fully recyclable corrugated cardboard packaging solution for three integrated electrical switchgear products, enhancing product protection while reducing material usage and supporting a more circular supply chain.
The newly designed fibre-based packaging is engineered to securely protect heavy and delicate switchgear components throughout manufacturing, transportation, and storage. It is also compatible with automated production lines, allowing for faster and more efficient packaging operations.
Due to the significant weight of the switchgear products, they must be handled from the side using industrial manipulators. To address this, the packaging securely holds the moving components in place, minimizing the risk of damage during transit while ensuring safe handling across the supply chain.
The packaging can be assembled in under one minute with minimal folding, making it suitable for high-volume automated production environments. An openable side tray provides a stable base, enabling the products to be firmly secured, while corrugated cardboard endcaps and inserts offer additional protection for sensitive components such as metal connectors.
To safeguard greased parts from dust, the solution also includes a polyethylene protective bag. Multi-layer corrugated cardboard construction enhances durability without compromising recyclability, helping reduce reliance on less sustainable protective materials.
DS Smith subjected the packaging to rigorous drop testing to validate its strength and impact resistance. Its compact design minimizes empty space, reducing packaging material requirements while lowering freight and storage costs.
Levente Szabó, Cluster Director at DS Smith Hungary, said the project demonstrates how fibre-based corrugated packaging can successfully combine protection, handling efficiency, sustainability, and ease of assembly for complex industrial products.
The collaboration reflects the growing shift toward recyclable, fibre-based industrial packaging solutions that improve operational efficiency while supporting sustainability goals across global supply chains.
