The Innovative Future of Industrial Packaging
A must-read for industrial professionals to stay ahead
From automotive and electronics manufacturers to heavy-duty machine producers, businesses worldwide are reevaluating how packaging can drive cost efficiency, meet sustainability targets, increase supply chain efficiency, and comply with new packaging regulations.
In this brochure, we explore the latest trends, actionable insights, and case studies showing how the right packaging strategy can transform these challenges into measurable results.
Keep up with the packaging evolution
Addressing climate change is among the most pressing global challenges confronting policymakers and enterprises, regardless of their size or sector. Packaging is a key factor in mitigating this issue.
Discover real-life examples and insights that show how the right packaging can turn challenges into opportunities.
INSIGHTs
65% of global consumers are concerned about climate change, accelerating the transition to a circular economy. With growing pressure from both regulators and customers, packaging must do more than protect products. It must help advance the transition by reducing CO₂ emissions, optimizing space, and minimizing waste across the supply chain.
There’s
clear
room for improvement: 92% of European businesses use oversized boxes, resulting in
160k tons of unnecessary cardboard used each year, which adds up to
€45 mln in completely avoidable annual costs.
2030 marks a key milestone
for EU member states to meet packaging waste reduction targets under the Packaging and Packaging Waste Regulation (PPWR), which is designed to reduce the environmental impact of packaging across all industries by:
Minimizing weight and use of virgin materials. Ensuring all packaging on the EU market is recyclable.
Limiting void space for grouped, transport, and e-commerce packaging to no more than 50%.
Establishing mandatory reuse targets from 40 to 100% for transport packaging, excluding cardboard from these targets.
Turn regulation into results
Innovative Industrial Packaging: Trends & Insights
As PPWR and void space optimization rules take effect, packaging minimization is no longer optional – it’s mandatory. However, with the right strategy, compliance can also become an opportunity to enhance supply chain efficiency and reduce costs.
Together with our partner, Schréder, we turned that opportunity into real results. By redesigning their packaging with our Trapezoid Box, we achieved pallet size reduction from 1200x1200 to 1200x1000 and eliminated empty space, allowing 60% more products per truckload. All while maintaining product protection and production efficiency.
What powers the industry?
Key industrial trends
As sustainability goals become increasingly stringent and automation reshapes production lines, industrial packaging must do more than protect a product.Let's examine how it has become ta key driver of innovation and value creation for many electronics brands.
2 out of 3 industrial producers
recognize the full impact of packaging on their supply chain, treating it as a strategic tool for driving sustainability, automation, and improving customer experience. Impressive business results from implementing a smart packaging strategy not only help explain, but also accelerate the transition toward designs that reduce waste, streamline logistics , and improve the unboxing experience.
Here s what a well executed industrial packaging strategy can generate:
Up to 60% more efficiency in pallet and transport utilization.
Enhanced perception among consumers thanks to a premium, sustainable design.
Reduced total costs through optimized logistics and waste minimization.
Future ready compliance with PPWR and zero waste targets.
to learn how our team can help you optimize your packaging for the future.
INSIGHTs
The fine art of balancing
Designing industrial packaging involves balancing multiple priorities beyond just material quality. Precision engineering, extensive category knowledge, and a proactive approach are crucial to developing an effective packaging solution that:
Provides complete product protection across every stage of transport and handling. Optimizes space and reduces logistics costs, improving supply chain efficiency. Remains fully recyclable and plastic-free, aligning with sustainability goals and PPWR standards. Supports smart manufacturing and fit-to-size automation, streamlining production processes. Delivers a clean, premium unboxing experiencethat reinforces brand value.
Meeting these challenges takes innovation at every stage of the packaging process. At DS Smith, we combine data, design, and technology to create solutions that are smarter, more efficient, and ready for the future of your business and the industry.
3D & 4D Design Modeling
We simulate performance and optimize materials before production, testing efficiency virtually, and reducing waste.
Next-Gen Materials
Fiber based innovations that replace single use plastics and prepare your business for the PPW R targets.
Circular Design Metrics
Every concept is measured against our proprietary sustainability and performance indicators to ensure full circularity.
Fit-to-Size Automation
Tailored packaging designs that minimize void space and material use, while maximizing logistics efficiency.
Smart Manufacturing Integration
Solutions engineered to work seamlessly with robotic, automated, and digitally controlled production lines.
Lifting standards in packaging with heavy-duty innovation
Fronius International is an Austrian, familyowned technology company operating in welding, solar energy, and battery charging systems. With 37 subsidiaries across five continents and 6,700 employees, Fronius required a robust, efficient, and sustainable packaging solution for its compact, 15.5 kg welding machine.
Fronius TransSteel 2200C welding machine packaging expectations:
Must be suitable for transport by truck, ship, plane, andpallet
Must endure global shipping
Must with pre-erected, modular components assemble in under 1 minute
Must be 100% recyclable
Must suspend the machine to with the ground or sides prevent contact
Must withstand and drop vibration tests
The DS Smith team, in close collaboration with Fronius, developed a modular, plastic-free corrugated packaging solution with pre-erected components. This partnership ensured that every design decision balanced protection, sustainability, and ease of use.
Accessory trays were tailored for multiple configurations, enabling faster assembly and greater flexibility across product variants. The results speak for themselves – improved operational efficiency, reduced logistics costs, and a premium unboxing experience that reflects the high quality of Fronius’ products.
Awarded quality
This innovative solution won the WorldStar Packaging Award 2025 in the Electronics category at IPACK-IMA in Milan, recognizing DS Smith’s reputation for combining performance, sustainability, and design excellence.
Discover the future of responsible industrial packaging.
