How Sustainable Packaging Is Cutting Costs and Emissions for European Manufacturers
Two major packaging innovations are helping European manufacturers cut costs and reduce environmental impact. Stora Enso's recyclable Papira foam now protects delicate optical equipment for Thorlabs Sweden, while DS Smith's Fanfold solution has transformed logistics for Greece's Elvial. Both developments replace fossil-based materials with sustainable alternatives while improving product safety in transit. Stora Enso worked with Emballageteknik to adapt its wood-based Papira foam for Thorlabs Sweden's sensitive optical and electronic components. The material shields equipment from vibrations, impacts, and knocks during transport. Unlike traditional fossil-based foams, Papira is fully recyclable and biodegradable, offering the same shock absorption without environmental harm.
DS Smith's Fanfold packaging, introduced for Elvial in Greece in 2022, has already delivered measurable benefits. By optimising truck loads—fitting up to 33% more products per shipment—the solution cut logistics costs by 20%. Transport emissions fell by 25%, improving Elvial's CO₂ balance. The accordion-style design, made from a single corrugated cardboard sheet, replaces multiple layers previously used, reducing waste and assembly time. The Fanfold system also adapts to different product sizes, providing natural cushioning for heavy aluminium items during international freight. DS Smith has since expanded its use across Greece's industrial sector. Meanwhile, the company recently partnered with Raymarine to replace single-use plastics in radar product packaging with fibre-based materials.
Both innovations demonstrate how sustainable packaging can lower costs and emissions while maintaining product protection. Stora Enso's foam and DS Smith's Fanfold have already proven their effectiveness in real-world logistics. Manufacturers now have scalable alternatives to plastic and fossil-based materials for fragile and heavy goods alike.
