DS Smith, an International Paper company, and SOMFY have developed a fully recyclable corrugated cardboard packaging solution designed to protect roller shutter motors during transportation while replacing expanded polystyrene (EPS) inserts. The solution has progressed to operational deployment and supports SOMFY’s efforts to increase the use of recyclable industrial packaging materials.
Developed by DS Smith’s design teams in Kunheim in collaboration with SOMFY, the project focused on improving packaging recyclability while maintaining product protection requirements across storage and transport operations. The development process included evaluation of product specifications, manufacturing conditions and end-use requirements, followed by testing and refinement of multiple design concepts.
The final packaging design uses Kraft EE (Electrical Grade) corrugated board and is intended to provide the strength and durability required for industrial handling and distribution environments. The inserts were developed as a modular system capable of accommodating thirty-four different engine lengths and adaptable across four box sizes. According to the companies, this standardisation helps reduce logistical complexity and supports production efficiency through simplified assembly.
The companies also stated that the reduced volume of corrugated cardboard compared with EPS contributes to lower storage requirements and improved space utilisation at logistics facilities. Following an initial trial phase, the packaging solution has moved into operational use under commercial conditions.
Benjamin Chedal, Sales, Marketing, and Innovation Director, DS Smith Packaging France, said: “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.”
Tony Faure, Chef de Projet, SOMFY, added: “The eco-design of our products and the sustainability of our practices are at the heart of the SOMFY Group’s decarbonization strategy.”