DS Smith supplies fibre-based fruit export trays in Greece for transatlantic shipments exceeding 45 days

GREECE – DS Smith has supplied closed tray packaging for kiwifruit and fresh fruit transport to growers in Greece, a 10kg fibre-based format with ventilation, designed for transatlantic shipments exceeding 45 days.

The trays comprise a body, base, and top lid with die-cut side openings for ventilation. The lid is built into the structure, and the format can be adjusted for different needs. 

They are made from virgin paper selected for strength and durability as an alternative to plastic packaging. 

Before export, producers can insert their own atmosphere-management and temperature-control bags into the sealed trays to manage travel conditions.

The Challenge of Long-Distance Fruit Transport

Fresh fruit shipped across the Atlantic faces multiple threats: moisture loss, temperature fluctuation, physical damage from stacking, and ethylene buildup from ripening fruit. 

Plastic packaging has been the default because it is lightweight, water-resistant, and can be engineered with ventilation holes. 

However, plastic trays are difficult to recycle, and consumer-facing brands face pressure to reduce plastic packaging. DS Smith’s fibre-based tray is designed to match the functional requirements of plastic while offering full recyclability. 

The use of virgin paper is notable; recycled fibre would not have the strength needed for 45-day transatlantic shipments. 

By using virgin fibre for the structural components, the tray provides the mechanical strength needed for stacking, while the overall package remains recyclable after use.

Circular Design Metrics

DS Smith applied its Circular Design Metrics tools to assess and compare the circularity of the packaging design across eight measures, including supply chain efficiency, recyclability, material use, carbon footprint, and renewable source. 

The tool quantifies the environmental impact of different design choices, allowing DS Smith to optimize the tray’s material thickness, ventilation hole pattern, and stacking geometry before physical prototyping. 

The lightweight design reduces material use and shipping weight, which is critical for transatlantic freight where weight directly affects fuel consumption and CO₂ emissions. The trays are fully recyclable in standard paper recycling streams.

Packing Efficiency and Branding

The tray’s simple structure supports a more efficient packing process and can be assembled on automatic forming machines with either faster or reduced packing time. 

For a grower packing thousands of trays per day, minutes saved per pallet add up to hours per shift. 

The outer surface can also be used for different printing methods and branding, allowing Greek kiwifruit exporters to differentiate their product in overseas markets. 

Giorgos Filippoglou, DS Smith Hellas Greek cluster packaging division managing director, stated that at DS Smith, sustainability and innovation are at the core of every packaging solution designed, especially for critical sectors such as agri-food where product safety, freshness, and quality are paramount. 

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