DS Smith launches corrugated cardboard trays for automotive headlights

LONDON –  DS Smith Tecnicarton has introduced an innovative solution for the automotive industry with its new corrugated cardboard trays designed specifically for transporting headlights. 

These trays, crafted entirely from recyclable corrugated cardboard, aim to replace traditional expanded polypropylene (EPP) solutions, offering a greener alternative without compromising on functionality.

The trays feature a unique double fingerprint die-cut design, which ensures secure positioning for both lightweight and heavy headlights. 

The design prevents damage during transit or storage, addressing the critical need for reliable protection in the automotive supply chain. 

According to DS Smith, the trays are engineered for efficient stacking, optimizing storage space and streamlining logistics for manufacturers handling sensitive components.

Antonio Cebrián, Commercial Director at DS Smith Tecnicarton, emphasized the trays’ versatility and sustainability. 

“Our corrugated cardboard trays can be manufactured quickly, meeting the same protection standards as traditional plastic alternatives,” he stated. 

“We offer a flexible, cost-effective solution with low tooling costs, available globally for automotive logistics, helping our customers achieve their sustainability and circular economy goals.”

These trays serve as a vital contingency option, acting as an alternative to returnable plastic packaging during supply chain disruptions, such as vehicle malfunctions, software issues, or unforeseen global events. 

Their integration into larger packaging systems also allows manufacturers to accommodate higher product volumes, enhancing operational efficiency.

In a statement, DS Smith highlighted its commitment to advancing sustainable packaging for the automotive and industrial sectors. 

The company focuses on developing single-use and returnable solutions tailored to the needs of manufacturers dealing with bulky or delicate items, ensuring both environmental responsibility and logistical reliability.

Adding to this development, recent industry updates reveal DS Smith’s broader push toward sustainability. 

In April 2025, the company partnered with TPV Automotive to create plastic-free packaging for BMW’s car wheel carriers, using recyclable corrugated cardboard to protect complex components during transit. 

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