DS Smith has partnered with Somfy, a global specialist in automated and connected home and building equipment, to develop a fully recyclable corrugated cardboard solution designed to protect roller shutter motors during transportation replacing conventional polystyrene inserts in the process.
The collaboration has resulted in a large-scale operational deployment and represents a significant step forward for Somfy in its transition towards more sustainable and circular industrial packaging practices.
Led by DS Smith design teams based in Kunheim, the project was developed in close collaboration with Somfy with one clear goal: to replace plastic and improve the recyclability of packaging without compromising on the quality of product protection during storage and transport.
From the outset, both teams worked through in-depth discussions around product specifications, integrating constraints related to production requirements and real-world usage conditions. This open, iterative approach enabled the development of several successive concepts, each of which was tested, adjusted, and optimised throughout the project lifecycle.
The resulting inserts are manufactured from Kraft EE (Electrical Grade) corrugated board, ensuring the robustness and durability required for motor protection in transit. The system has been designed to be modular, accommodating thirty-four different engine lengths and adaptable across four box sizes a combination that contributes to a measurable reduction in logistical complexity.
The assembly process is described as quick and straightforward, meeting industrial production rates and requirements. Furthermore, the compactness of corrugated packaging compared to Expanded Polystyrene (EPS) enables a significant reduction in storage volume, generating immediate space savings across logistics sites.
Following a successful trial order, the solution has now entered its operational phase, where it continues to demonstrate strong performance under real-world conditions. This recyclable corrugated packaging marks a practical, scalable transition away from single-use plastic protective materials.
Benjamin Chedal, Sales, Marketing, and Innovation Director at DS Smith Packaging France, stated: “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, Project Manager at Somfy, added: “The eco-design of our products and the sustainability of our practices are at the heart of the Somfy Group’s decarbonisation strategy. We are delighted to have collaborated with DS Smith on the deployment of this cardboard packaging solution: it marks an important step that facilitates handling and recycling for our professional customers, is made from renewable material, and does not compromise on the quality and protection requirements of our products.”
The project underlines a broader industry direction where sustainable packaging and circular industrial packaging approaches are being pursued not as aspirational commitments but as operationally deployed realities. The move away from polystyrene replacement solutions towards fibre-based alternatives continues to gain traction across manufacturing and logistics sectors globally.
