Eliminating 13.2 tons of plastic with a corrugated packaging solution for kitchen worktops

The Challenge

In 2021, Socoda expanded its operations to Panama, launching exports of high-value, heavy-duty products like kitchen countertops. These items were originally packaged in bubble-wrap for extra protection to safeguard them during transportation. However, this packaging fell short of expectations, leading to a 32% return rate due to damage to components such as grills, knobs, and gas systems.

Our challenge was to design an innovative corrugated packaging solution that would provide comprehensive protection for the products, eliminate the need for materials like bubble wrap, and reduce returns to zero.

The Approach

With the help of our SupplySmart process, our design team conducted a thorough analysis of Socoda’s logistics chain to optimise packaging and enhance overall efficiency. This analysis highlighted the need for an fully corrugated cardboard solution with integrated protection features. 

As a result, we developed a two-piece packaging system featuring reinforced corners and partial viewing windows. This innovative design eliminated the need for bubble wrap while ensuring the protection of the most vulnerable parts of the products during transit.

The Result

The new corrugated packaging was a resounding success, enabling Socoda to eliminate 13.2 tons of plastic and reducing its CO₂ footprint by an impressive 32.8 tons between 2023 and 2024.

By eliminating previously used materials such as bubble wrap, plastic, and foam, Socoda also managed to achieve a cumulative savings of over $82,000 (2023-2024) through resource optimization and reduced operational costs.

Socoda reported that the new design also eradicated product damage, resulting in zero returns from 2023 to 2024, improving customer satisfaction.