Assembly lines put together different components from various suppliers to create a final product, be it a car, a refrigerator or an air conditioner. These industrial ‘Frankensteins’ lead to thousands of journeys for components every day with two fundamental expectations: that they arrive on time and in perfect condition.
Furthermore, in recent years, concerns about climate change have also meant that people are starting to pay attention to the environmental impact of each journey.
All these factors play a key role in the design of efficient component packaging.
Evolution of Component Packaging
Since the dawn of time, humans have understood the benefits of exchanging objects with neighbouring communities. For all this time, the important thing has always been for the goods to arrive safely.
With the turn of the millennium, climate change became, in the words of former US Vice President Al Gore, an ‘inconvenient truth’. The packaging industry accepted the role it had to play and began to research more sustainable packaging solutions.
Traditional Packaging Materials
For many thousands of years, humans transported their goods in whichever containers were closest at hand: clay pots, leather wineskins, wooden chests, metal pots, glass containers, barrels, etc.
The 19th Century saw the emergence of tin and corrugated cardboard, while the 20th Century will undoubtedly go down as the age of plastic.
Advances in Component Packaging
In the second half of the 20th Century, the general situation of peace and prosperity in the world led to an exponential boom in industry and trade. For decades, all that mattered was selling, shipping, manufacturing and selling again.
However, growing environmental concerns are now changing the rules of the game. The market is demanding more sustainable products and industry understands that sustainability needs to be incorporated throughout the supply chain.
The way that components are transported is just another factor in this equation. This has led to the emergence of ‘eco-friendly component packaging’—a packaging model with a lower carbon footprint that does not compromise on safety during shipping.
At first glance, wood and cardboard are seen as the most sustainable, while plastic is being demonised. But this mistrust towards plastic is largely due to a lack of knowledge about its potential in the circular economy (such as reuse, return and recycling). And let’s not kid ourselves, this is also the legacy of poor waste mismanagement over many decades.
However, if well managed, plastic can be used to develop highly cost-effective and sustainable component packaging solutions. Furthermore, it is now possible to design packaging using plastics from renewable and 100% recyclable sources, such as NEOPS®.
EPP, EPS and EPE Packaging Solutions
EPS Packaging
Expanded polystyrene (EPS) is a plastic foam which is 98% air. It is lightweight, shock-absorbent, inert and breathable, four characteristics that make it one of the most sought-after component packaging materials in the industry for non-returnable shipments.
Despite concerns about its potential environmental impact, LCA studies show that the carbon footprint of EPS packaging is lower than that of other materials, particularly for white goods and large electronic devices. In addition to other pieces of research, this is particularly shown by a study on TV packaging carried out by the European Manufacturers of Expanded Polystyrene Packaging (EUMEPS Packaging) in collaboration with the independent consultant PricewaterhouseCoopers (PwC)/Ecobilan.
EPP Packaging
Expanded polypropylene (EPP) is an expanded foam that has a bead structure and is 95% air. Its composition and mechanical properties make it extraordinarily light while maintaining a high strength-to-weight ratio. In addition to these two qualities, there is a third: EPP packaging is washable, making it reusable and returnable in closed returnability systems.
Expanded Polyethylene (EPE)
EPP can be combined with polyethylene foam or expanded polyethylene (EPE) to create customised inner compartments in EPP packaging. This material offers similar protection and cushioning to EPP but with lower density. However, it can be created in different densities, depending on its final application.
EPE foam provides excellent insulation and is resistant to water, oils and many chemical products. All these characteristics make it a good alternative to EPS as a packaging material, albeit at a somewhat higher cost.
Unlike EPS and EPP, EPE is not moulded but cut to achieve customised solutions. This makes it possible to produce quick and customised solutions at a lower cost. Undoubtedly, it is an excellent protective packaging alternative for short and immediate production runs.
Advantages of EPP and EPS Packaging
EPP and EPS have become hugely popular for shipping and handling packaging in the component packaging industry due to their lightness, impact resistance, recyclability, mouldability and lower carbon footprint.
- Lightness. This reduces the weight of the final packaging.
- Excellent shock absorption. High protection against hazards during transport and handling. In particular, EPP has a high ability to recover its shape after impacts.
- Returnable. EPP packaging can be washed (even in industrial dishwashers) and re-circulated multiple times. This makes it a cost-effective and circular option for component packaging.
- 100% recyclable by mechanical processes (at a lower cost and lower environmental impact). It’s no wonder that this recyclable component packaging is now being included in the select category of ‘green’ component packaging.
- Lower carbon footprint than other fossil-based materials and even some plant-based materials.
- Easy to mould. Its physical structure makes it possible to manufacture customised packaging using specific moulds. An ideal protective component packaging option that also optimises material and space.
Custom Packaging Design
Your product is unique, and your packaging should be too. This principle is becoming increasingly important in packaging design. And this is not just for aesthetic reasons. Customisable component packaging offers enormous benefits.
Even more so if you choose to work with EPS or EPP.
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Ecodesign according to new regulations
The new European legal framework for packaging requires the use of raw materials to be reduced to generate less waste. Plastic foams, which are almost entirely air, are great options for the eco-design of packaging and protective elements.
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More affordable shipping with lower emissions
Every extra kilogramme in freight translates into extra euros in fuel. This is an extra cost for the manufacturer and a drag on the company’s overall carbon footprint. Opting for lightweight materials, such as EPP and EPS, makes it possible to develop packaging solutions for lightweight components that adequately address both issues.
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Transport capacity
Standard packaging always leaves cubic centimetres of packaging unused and still takes up space in transport and storage. The customised eco-design of EPS packaging allows the number of packages per pallet to be increased by up to 25% as some cases of our customers’ projects show.
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Secure packaging
Vibrations and potential impacts to a package during transport can be critical, especially for fragile or sensitive objects such as digital technology components. Adapting the packaging to the exact shape of each item reduces losses due to breakage and damage.
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Cost optimisation
Optimising weight, space and safety has an immediate consequence: a significant reduction in logistics costs. It also reduces the dreaded returns due to breakages that affect the bottom line and the prestige of your brand.
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Customer experience
“There is not second chance to make a good first impression”. If a package and its contents arrive in perfect condition and are presented neatly and tidily, this reflects very positively on the supplier and will contribute towards customer loyalty.
6 Trends in the Component Packaging Industry
Component packaging trends include the following:
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Environmentally friendly packaging
There are no excuses: packaging must leave the smallest possible environmental footprint throughout the entire value chain. It is the first and most important of B+P Consultants’ packaging trends for 2023.
This trend responds to the requirements of the European Green Deal and has been dubbed ‘eco-friendly’ or ‘sustainable packaging’. It involves working with lightweight, biodegradable, compostable, recycled or more easily recycled materials.
The new plastic taxes already in force in countries such as Spain and France are set to give a definite boost to packaging with recycled plastics.
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Customisation
Customised packaging has an immediate impact on carbon footprint and logistics costs. Marketing experts also believe that it has added benefits for branding and reducing the damage caused by breakages.
According to the 2019 Trends in Personalization Report by Researchscape International and Evergage, Inc.,98% of marketers believe that personalisation advances customer relationships. In particular, 70% say that personalisation improves customer experiences, increases loyalty and generates measurable ROI.
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Storytelling
It’s not just the what but the how. Packaging is a silent salesman. It tells us whether a supplier is meticulous, if they offer value that sets them apart… These small details help to attract and retain the loyalty of the end customer.
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Simple and optimised
In logistics, empty space has an environmental footprint. A study by DHL warns that 24% of the volume in e-commerce packaging is empty space. A similar situation applies to overpacked shipments.
The trend is clear: packaging must fit every product like a glove. Overpacking is a waste of material and has a negative impact on the environment.
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Traceability and connectivity
Blockchain, smart packaging and other smart coding solutions, digitisation and connectivity solutions are already a reality in smart component packaging. It is expected to grow exponentially over the coming years.
This trend is no surprise and we at Knauf Industries wish not to lag behind: our KOMEBAC connected box allows you to incorporate these digital devices for proactive logistics management.
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Security
Returns for goods broken or damaged in transit are a nightmare for the industry, costing millions of euros, and can stain a company’s reputation.
A customised design with shock-absorbing materials is key to achieving durable component packaging that ensures safety throughout the logistics chain.
Innovative Packaging Solutions
When choosing the packaging for your products, it’s possible to opt for standard solutions and adapt them in the most convenient way for your products. However, customised solutions offer better results and added value.
Packaging experts such as Knauf Appliances offer customised eco-design packaging services to meet specific product requirements, reduce losses due to product breakage or damage and improve the customer experience. These are qualities that, in the long run, translate into more sales.
Our ID Lab professionals apply the principles of Design Thinking and eco-design with prototyping and software simulation to achieve appropriate and customised solutions that fully meet the needs of your business. Customised packaging that will give you the best marketing results and, of course, with the utmost respect for the environment.
Because your packaging should leave a mark on your customers, not on the planet.
FAQ About Innovative Component Packaging Solutions: EPP & EPS
Expanded polypropylene (EPP) is an expanded foam that has a bead structure and is 95% air. Its composition and mechanical properties make it extraordinarily light while maintaining a high strength-to-weight ratio. In addition to these two qualities, there is a third: EPP packaging is washable, making it reusable and returnable in closed returnability systems.
Expanded polystyrene (EPS) is a plastic foam which is 98% air. It is lightweight, shock-absorbent, inert and breathable, four characteristics that make it one of the most sought-after component packaging materials in the industry for non-returnable shipments.
Packaging experts such as Knauf Appliances offer customised eco-design packaging services to meet specific product requirements, reduce losses due to product breakage or damage and improve the customer experience. These are qualities that, in the long run, translate into more sales.
