DS Smith replaces plastic foam with fiber-based packaging for Raymarine Radar Products, cutting CO₂ emissions by 60%

UK – DS Smith has partnered with marine electronics manufacturer Raymarine to develop a fiber-based packaging solution that replaces single-use plastic in the company’s radar product line.

The new design uses corrugated cardboard to substitute expanded polyethylene (EPE) foam, reducing annual CO₂ emissions by more than 60% while maintaining the durability and protective performance required for long-haul marine electronics shipments.

Raymarine’s radar systems, often transported across diverse climatic conditions, previously relied on EPE foam for cushioning.

The new solution developed by DS Smith’s design team uses corrugated materials engineered to absorb impact, withstand vibrations, and protect delicate components during international transit.

Andrew Smith, vice president for Supply Chain at Raymarine, said the redesign supports both product safety and sustainability goals.

“The new packaging ensures that products from our radar range are well-protected during transit while also meeting the demands of diverse climatic conditions and long-haul international shipping,” he noted.

Levente Szabó, cluster director at DS Smith Hungary, highlighted the wider sustainability value.

“This packaging for Raymarine is made from 84% recycled content versus 40% in previous packaging, and it is fully recyclable at the end of life. We have successfully replaced EPE, and we can support manufacturers in consumer and industrial sectors.”

The redesigned packaging incorporates a perpendicular corrugated cardboard flute at a 90-degree angle to enhance rigidity and shock resistance.

DS Smith also introduced crumple-zone layers designed to deform on impact, absorbing energy to protect sensitive radar components. Additional fiber-based air cushions provide further stability.

The structure includes precisely shaped inserts to hold Raymarine’s Quantum radar units securely, while a dedicated folded-cardboard technique ensures dimensional accuracy and strength.

An integrated box compartment allows accessories and cables to be packaged separately without additional plastics.

Logistics efficiency and circularity benefits

The packaging’s modular design allows customization across multiple product sizes while supporting efficient warehousing.

Corrugated inserts ship flat, reducing pallet requirements by 75% compared with earlier solutions where foam components were transported as bulk items.

DS Smith evaluated the design using its Circular Design Metrics tool, assessing recyclability, renewable content, carbon footprint, and supply chain efficiency.

The tool enables customers to benchmark sustainability performance across eight indicators, supporting more circular packaging decisions.

The shift away from EPE aligns with wider efforts across electronics and industrial sectors to remove single-use plastics from protective packaging.

Companies like Schneider Electric and Bosch have recently expanded their use of molded pulp and corrugated inserts in component shipping, while major marine electronics competitors are testing reusable transit packaging for high-value systems.

DS Smith’s collaboration with Raymarine underscores growing momentum toward fiber-based cushioning solutions that meet both regulatory expectations and brand sustainability commitments.

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