One person must be able to erect and load the packaging alone,” was one of the customer’s key requirements. No easy task when optimizing overseas transport packaging for drive shafts. The client: an international supplier of joints and shafts for the automotive industry. The previous packaging caused high transportation and storage costs due to its large-volume EPS padding. Disposal was also made more difficult by the use of these cushions, which made single-material disposal impossible.

The DELTA team was therefore not only challenged with regard to simple integration into the production process, protection and safety of the components to be packaged. Energy efficiency and sustainability criteria also had to be met.

The packaging experts first carried out a thorough analysis on behalf of the customer. This involved examining processes and working out optimization approaches. The existing outer packaging (ring, base, lid) had to continue to be used.

Based on this, DELTA developed a single-material solution made entirely from corrugated cardboard.
There are usually two major challenges when switching from reusable to disposable packaging. Either it requires very complex constructions to be erected or the utilization per packaging unit is reduced, sometimes significantly. Thanks to carded trays and simple U-cuts, the new solution enables an extremely simple set-up and identical utilization to the original concept.

Overall, the result is a safe and compact packaging solution with high efficiency, which reduces transportation costs and can be easily disposed of on delivery to the customer thanks to flat blanks.