DS Smith has introduced a fibre-based corrugated packaging system designed for the transport of automotive chassis, offering an alternative to conventional reusable metal containers used in automotive supply chains.
Developed by its Tecnicarton division, the solution is constructed entirely from corrugated cardboard and designed as a mono-material structure. It includes a recyclable box pallet system with a base, cover, and integrated positioners that hold heavy chassis components securely during handling, storage, and transportation.
The development addresses operational challenges associated with returnable metal packaging, particularly when disruptions prevent containers from circulating efficiently between suppliers and OEM facilities. The fibre-based format provides a single-use alternative that can be deployed quickly to maintain production continuity during supply chain interruptions.
According to the company, the packaging is designed to meet the same performance requirements as non-fibre solutions while offering weight reduction benefits that support handling efficiency and transport optimisation across road and sea freight. The structure also incorporates replaceable inserts and dividers to improve load stability and space utilisation.
The system is compatible with existing manufacturing and assembly processes, enabling direct-to-line delivery without the need for repacking or intermediate handling. This is expected to reduce internal logistics operations and improve sequencing accuracy for automotive components.
As a mono-material solution, the packaging is fully recyclable without the need for separation, supporting circularity objectives. The design has previously received recognition at the Liderpack Awards and the WorldStar Global Packaging Awards.