Corrugated packaging alternative to polystyrene introduced for shutter motor protection

DS Smith, an International Paper company and a leading provider of sustainable packaging solutions made from cellulose fibres, and SOMFY, a global specialist leader in automated and connected home and building equipment including automated shutters, blinds, curtains, and gates, have developed a fully recyclable corrugated cardboard solution to protect for roller shutter motors during transportation and replace polystyrene inserts.

The innovation has resulted in a large-scale operational deployment and a significant step forward for SOMFY in its transition towards the utilisation of more sustainable and circular industrial packaging.

Co-creation for innovation

Led by the DS Smith design teams in Kunheim in close collaboration with SOMFY, the project has addressed a single objective: to replace plastic and improve the recyclability of packaging without compromising on the quality of product protection throughout storage and transport.

From the outset, the DS Smith and SOMFY teams collaborated closely and their work relied on in-depth discussions around the specifications, allowing for the integration of product constraints, production requirements, and real-world usage conditions. This open approach enabled the development of several successive concepts, which were tested, adjusted, and optimized throughout the project.

A standardized, adaptable, and high-performance industrial solution

Made from Kraft EE (Electrical Grade) corrugated board, these cardboard inserts guarantee robustness and durability. Designed to be modular, the system accommodates thirty-four different types of engine lengths and can be adapted to four box sizes, thus contributing to a significant reduction in logistical complexity. The quick and easy assembly process is designed to meet industrial production rates and requirements.

In addition, the compactness of the cardboard compared to Expanded Polystyrene (EPS) allows for a significant reduction in storage volume, generating immediate space savings at logistics sites. Following a successful trial order, the project is currently during its operational phase and demonstrating the packaging solution's successful performance under real-world conditions.

This innovation fully illustrates DS Smith’s ambition to support its customers in developing increasingly sustainable packaging solutions. We are very proud of the rollout of this concept, which has been adapted to numerous SOMFY product formats, demonstrating its modularity, relevance, and long-term viability, both in terms of innovation and the materials used.

Benjamin Chedal, Sales, Marketing, and Innovation Director, DS Smith Packaging France.

The eco-design of our products and the sustainability of our practices are at the heart of the SOMFY Group’s decarbonization strategy. We are delighted to have collaborated with DS Smith on the deployment of this cardboard packaging solution: it marks an important step that facilitates handling and recycling for our professional customers, is made from renewable material, and does not compromise on the quality and protection requirements of our products.

Tony Faure, Chef de Projet, SOMFY.

DS Smith has a target-led sustainability strategy and is committed to leading an industry-wide transition to the circular economy, while delivering sustainable circular solutions to customers across industrial and automotive, food, and beverage, FMCG (Fast Moving Consumer Goods), automotive, and e-Commerce sectors, across thirty-four countries worldwide.