DS Smith’s recyclable corrugated packaging replaces plastic in Schneider Electric’s heavy-duty switchgear

UK – DS Smith has partnered with Schneider Electric to develop a fully recyclable corrugated cardboard packaging solution for three types of electrical switchgear products, with the award-winning design engineered for one-minute assembly on automated lines while cutting material use and improving supply chain circularity.

The packaging solution, announced on 28 July 2026 in London, supports Schneider Electric’s sustainability ambitions by reducing material use and improving circularity in the supply chain. 

The design, which received the Electronics category award at the 2026 WorldStar Global Packaging Awards, addresses the unique challenges of transporting heavy-duty electrical switchgear products that can only be moved and packed from the side using an industrial manipulator. 

The switchgear components are integrated into the cabinet as part of the finished design, facilitating secure attachment to moving parts while ensuring easy handling during production and transportation. 

Fibre-Based Protective Structure Engineered for Heavy-Duty Industrial Products

The packaging incorporates an openable side tray that provides a stable base for anchoring products firmly in place during handling and transit. 

Moving parts are secured using corrugated cardboard sheet elements integrated into a separate endcap, while a polyethylene bag protects greased components from dust. Metal connectors are shielded by folded corrugated inserts, and multi-layered endcaps made from fibre-based materials provide maximum stability. 

The DS Smith team conducted drop tests as part of the design and compliance process to assess resistance to impact, shocks and potential structural damage. 

The compact design eliminates unused space to minimise material use while reducing freight and storage costs. 

By optimising the packaging structure, the solution reduces void space and ensures that only the necessary materials are used without compromising product protection.

Automation-Ready Assembly and Schneider Electric’s Sustainability Impact

Despite the packaging’s complexity, its components can be assembled in less than one minute on automated packaging lines with minimal folding required. 

The lightweight yet robust corrugated construction ensures that the packaging can withstand the rigours of global supply chains while remaining fully recyclable at end-of-life. 

Levente Szabó, Cluster Director at DS Smith Hungary, stated that achieving the correct balance between protection, handling efficiency, and sustainability is absolutely key, with the design demonstrating what can be achieved with fibre-based and corrugated cardboard solutions. 

The packaging complements Schneider Electric’s sustainability programme, which increased the share of primary and secondary packaging free from single-use plastic using recycled cardboard to 85 percent by late 2025. 

The award-winning solution demonstrates how circular design principles can be applied to complex industrial packaging, proving that fibre-based materials can replace traditional plastic and foam alternatives without compromising performance.

Subscribe to our email newsletters that provide busy executives like you with the latest news insights and trends from Africa and the World. SUBSCRIBE HERE