DS Smith replaces polystyrene inserts with recyclable corrugated cardboard for SOMFY roller shutter motors

FRANCE – DS Smith has collaborated with SOMFY to develop a fully recyclable corrugated cardboard solution for roller shutter motors, replacing EPS inserts with Kraft EE board that accommodates thirty-four motor lengths across four box sizes.

DS Smith’s design teams in Kunheim worked with SOMFY to replace plastic and improve recyclability without compromising on product protection during storage and transport. 

The assembly process is designed to meet industrial production rates and requirements.

Compared to EPS, the compactness of the cardboard delivers a significant reduction in storage volume, saving space at logistics sites. Following a successful trial order, the project is currently in its operational phase.

The EPS Replacement Challenge

Expanded polystyrene (EPS) has been the default protective packaging for fragile industrial components because it is lightweight, mouldable, and inexpensive. 

However, EPS is not widely recyclable, and its low density makes it costly to transport and store relative to its protective value. 

The cardboard solution uses Kraft EE (Electrical Grade) corrugated board, a material engineered for strength and rigidity without the weight and volume of EPS. 

The modular system’s ability to accommodate thirty-four different engine lengths means SOMFY can standardise packaging across its product range, reducing the number of SKUs in its packaging inventory. 

The four box sizes cover the entire product portfolio, simplifying warehouse storage and picking.

Logistics Efficiency

The compactness of the cardboard compared to EPS delivers a significant reduction in storage volume, saving space at logistics sites. 

For a manufacturer shipping thousands of motors annually, the difference between storing EPS inserts (bulky even before assembly) and flat-packed cardboard (stored as sheets and folded at the packing line) translates into warehouse square footage. 

The corrugated solution also reduces transport volume because boxes can be shipped flat to assembly points, while EPS inserts arrive pre-moulded, occupying their final volume from warehouse to packing line.

Industrial Assembly Rates

The assembly process is designed to meet industrial production rates and requirements. A protective packaging solution that slows the packing line is a non-starter for high-volume manufacturers. 

The cardboard inserts are designed for rapid assembly without tools, allowing SOMFY’s packing staff to maintain line speeds. 

The Kraft EE board provides the puncture resistance and crush strength needed to protect motors during multi-modal transport, road, sea, and rail, without adding excessive weight.

A Model for Industrial Packaging

The SOMFY collaboration follows DS Smith’s recent partnership with Elvial to introduce fibre-based Fanfold packaging for heavy aluminium products in Greece. 

Industrial packaging is shifting from single-use plastics to fibre-based alternatives, driven by customer sustainability targets and regulatory pressure. 

The SOMFY project is now in its operational phase, proving that corrugated can replace EPS in demanding protective applications.

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