DS Smith partners with TPV Automotive to deliver sustainable packaging for BMW wheel carriers

UK – Packaging leader DS Smith has teamed up with automotive components supplier TPV Automotive to develop an innovative, plastic-free packaging solution for BMW’s car wheel carriers, reinforcing both companies’ commitment to sustainable logistics.

The new packaging, made entirely from fibre-based corrugated cardboard, is custom-designed to accommodate the complex 3D shape of BMW wheel carriers.

DS Smith’s design team aimed to ensure maximum protection during shipping, preventing movement that could lead to damage.

Each car wheel carrier weighs approximately 8kg, with 20 units packed per pallet. The packaging is engineered to support up to 160kg per pallet, offering strong structural stability for long-haul transportation.

Its compact design also ensures it fits efficiently into shipping containers destined for BMW’s assembly facility in Asia.

Key to the innovation is the use of three-dimensional corrugated cardboard inserts that are pre-cut and delivered as flat sheets.

These are folded accordion-style to form snug, structural compartments that cradle each auto part precisely. The full solution comprises a cardboard pallet box, tailored base inserts, and a top-reinforcing flat panel that securely seals the package.

“Our designers had to think outside of the box—quite literally—to develop a unique and sustainable packaging solution for TPV Automotive,” said Jožica Hojnik, Subregional SMI Director at DS Smith. 

“The accordion-style folding inserts offer a particularly clever innovation, delivering both dimensional flexibility and protection using only recyclable materials.”

DS Smith’s focus on sustainable innovation extends beyond the automotive industry. Earlier this month, the company launched the GoChill Cooler, a recyclable and reusable alternative to traditional plastic and Styrofoam coolers.

Made from wax-free corrugated board, the cooler is food-safe, moisture-resistant, and designed to preserve food and drinks while reducing waste.

DS Smith reports that the GoChill Cooler matches the cooling performance of standard options while significantly lowering environmental impact.

According to a company survey, 77% of consumers would prefer the GoChill Cooler over disposable alternatives, and one in five respondents said they actively avoid brands still using Styrofoam.

These innovations align with DS Smith’s ‘Now and Next’ sustainability strategy, which focuses on accelerating the shift to a circular economy.

The company aims to extend the lifecycle of materials, reduce waste, and cut carbon emissions through smart, scalable packaging solutions.

From automotive logistics to outdoor leisure products, DS Smith continues to set new benchmarks in eco-conscious design—proving that functionality and sustainability can go hand in hand.

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