The challenge was clear: design a bed that was 100% made from corrugated cardboard, easy to assemble, strong, and durable. It needed to meet the highest sustainability standards, as the Olympic Committee publicly declared its ambition for the games to be the most sustainable in history. Smurfit Westrock, leveraging its expertise in circular design and recycling, rose to the occasion.

A Circular Design Approach

The entire process was built around the concept of circularity. From the initial raw material production to recycling at the end, Smurfit Westrock ensured that every stage of the bed's lifecycle adhered to sustainable principles.

1. Optimised Design: A team of expert designers worked tirelessly to create a bed that was not only functional but also sustainable. Through rigorous trials, they developed a solution that was patented, showcasing innovation unique to Smurfit Westrock.
2. Expert Production: The production process was carried out across four different plants in France, with quality and durability at the forefront.
3. Recycling Excellence: After the games, the beds were dismantled, crushed, and recycled into new raw materials, ready to be transformed into paper and corrugated packaging.

Innovation and Durability

Innovation is at the core of Smurfit Westrock’s packaging design process. The Olympic beds were no exception. Despite being made entirely from corrugated cardboard, the beds were:

• Durable: Rigorous testing, including 100-kilo drop tests in France and Japan, ensured that the beds met high durability standards.
• Functional: More than 16,000 beds were produced and used during both the Olympics and Paralympics, providing a practical, sustainable solution.

The Recycling Process

Once the Olympics ended, Smurfit Westrock demonstrated the full potential of its closed-loop recycling process:

1. The used beds were collected, crushed, and compacted into bales of clean corrugated cardboard.
2. These bales were transported to a paper mill in France, where they were turned into raw materials for new corrugated board.
3. The board was then printed, cut, and shaped into new cardboard boxes—continuing the cycle of sustainability.

A Showcase of Expertise

The success of the Olympic bed project highlighted the breadth of Smurfit Westrock’s capabilities, from paper production and design to manufacturing and recycling. The result was a solution that aligned perfectly with the Olympic Committee's sustainability goals.

• Quick and Easy Assembly: The beds were designed for fast and simple setup without compromising on strength.
• A Sustainable Legacy: By recycling the beds into valuable new materials, Smurfit Westrock reinforced its commitment to a circular economy.

The Results

This project was more than just about creating a bed—it was a testament to the power of innovation, sustainability, and circular design. Smurfit Westrock not only delivered a solution for the world’s largest sporting event but also set a new benchmark for sustainable manufacturing and recycling.

Arco Berkenbosch, Chief Innovation Officer commented "The final result was fantastic: a durable, sustainable, and innovative product that showcased the full potential of Smurfit Westrock's expertise."