DS Smith develops award-winning corrugated transport box for BWT’s MACH filter packaging, recycling

UK – DS Smith has developed an award-winning corrugated transport box for BWT’s MACH water filters, featuring a triangular insert that improves protection, cuts material use, and supports recycling.

The solution, which won a 2026 WorldStar Global Packaging Award in the Household category, was engineered to accommodate two different MACH filter models from BWT (Best Water Technology), a system widely regarded as a next-generation automatic backwash filter designed to protect domestic water pipes. 

Andreas Koch, Cluster Design & Innovation Manager at DS Smith Austria, stated that through close collaboration and use of the company’s Circular Design Metrics tools to measure packaging sustainability across eight key indicators, from materials utilisation to recyclability, a bespoke corrugated packaging solution was developed for optimal protection, sustainability, and efficiency.

Integrated Insert and Protective Construction Enable Efficient Production

A key feature of the design is an integrated, triangular-shaped corrugated cardboard insert that forms a flexible accessory compartment while shielding the MACH filters from shocks and unexpected impacts by separating the products from the base of the packaging casement. 

The transport box itself uses a double-wall corrugated cardboard construction, creating what DS Smith described as a rigid, durable, and strong format, while the compact design cuts material usage and reduces empty space within the pack. 

DS Smith also confirmed the transport box can be integrated into BWT’s existing packaging lines without disruption. 

The corrugated cardboard construction ensures the packaging is fully recyclable at end-of-life, supporting circular economy objectives. 

The design’s material efficiency also reduces transport weight and volume, contributing to lower logistics costs and carbon emissions across the supply chain.

Streamlined Production and Sustainable Branding

The finished packaging uses a natural brown corrugated board appearance, complemented by white flexographic printing on the outside surface. 

BWT CEO Andreas Weißenbacher stated that by lowering the number of plastic components used in product packaging, the company is conserving valuable resources and supporting more sustainable manufacturing practices, while the streamlined production setup, requiring only a single converting machine after corrugated production, creates significant cost efficiencies and improves overall production efficiency.

The packaging innovation was recognized at the WorldStar Awards, which annually honor outstanding performance in packaging innovation, sustainability, and functional design. 

The award-winning design demonstrates how corrugated packaging can replace plastic components while maintaining product protection and enhancing recyclability. 

DS Smith’s Circular Design Metrics approach ensures that sustainability is measured and optimized across the entire packaging lifecycle, from material sourcing to end-of-life recovery.

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