Mondi has developed a revised packaging solution for Stiebel Eltron’s water heater product range, reducing the number of corrugated board grades used by more than 75% while maintaining full product protection throughout the supply chain.
The corrugated packaging redesign covers packaging for instantaneous water heaters and small storage units that Stiebel Eltron ships to markets worldwide.
From 150 Variants to a Streamlined Range
Previously, approximately 150 corrugated packaging versions were in use across the product range. That level of variation introduced considerable complexity into procurement, manufacturing and logistics operations, making consistent management of the full range a significant challenge.
The packaging revision was carried out alongside a broader redesign of the boxes themselves. Mondi began with a detailed review of all existing corrugated packaging formats and identified the brown corrugated board grade it considered most suitable for each product group.
White Digital Printing Enables Design Flexibility
White digital printing was then added to support the new packaging design, enabling different pack designs and print quantities to be produced without additional set-up requirements. The approach also allows several variants to be combined within a single production run, enhancing operational efficiency further.
The printing method delivers accurate reproduction of fine details — including small text, QR codes and barcodes — on brown corrugated board, in line with the requirements of the updated packaging design.
Adam Fros, Head of Product Development for Building Services at Stiebel Eltron, said: “By supporting us through every phase of the packaging redesign, Mondi delivered a holistic concept that helped us reduce complexity and improve efficiency through a streamlined packaging approach. At the same time, white digital printing gives us the flexibility to adapt designs quickly, providing a scalable basis for future product launches.”
Mondi’s Broader Packaging Simplification Work
This development follows a separate project in which Mondi helped FIXIT GRUPPE streamline its paper bag packaging across European markets. That initiative reduced related greenhouse gas emissions by 135 tonnes of CO₂ compared to the prior year, reflecting the tangible outcomes that packaging efficiency improvements can deliver at scale.
The Stiebel Eltron corrugated packaging redesign stands as a further example of Mondi’s approach to reducing material complexity while supporting brand and operational requirements through advanced printing capabilities.