Winner at the WorldStar Packaging Contest

Earlier this year, Nefab won two Innovation and Technology prizes in the Hungaropack 2021, a local Hungarian packaging contest that qualified us for the WorldStar Packaging Contest 2022. Now we are happy to announce that last week, on the 15th of December, Nefab won awards at WorldStar Packaging Contest in the category “Packaging Materials and Components”.

A circular thermoformed solution for e-bike engines

One of the WorldStar awards recognized our work with a leading electronics manufacturer seeking a more environmentally friendly and durable alternative to paper pulp trays used for packing e-bike engines.

The solution: Circular packaging for electronics

As a solution, we developed thermoformed trays made from aPET, a 100% recyclable material that is more durable, protective, and in many ways more sustainable than trays based on paper pulp. Besides being more resistant to moisture and humidity in comparison with paper, the solution is also more cost efficient as it requires less material to be produced. In addition, Nefab’s thermoformed trays can be grinded, turned into raw materials, and applied to return and circular flows. This contributes to the CO2 emissions savings in our customers’ supply chains.

Environmental benefits of aPET trays: Reducing CO₂ and waste

Using Nefab’s ISO-certified environmental impact calculator, GreenCALC, we quantified substantial benefits:

• CO₂ emissions savings: 110 metric tons per year—equivalent to removing 23 passenger vehicles from the road.
• Waste reduction: 88,000 kg less waste generated each year compared to the previous solution.

“At Nefab, we save resources for a better tomorrow. We provide materials and solutions that can benefit our customers, society, and the environment. That is why our solution is a winner!”

These are the words from the winning Nefab team: Eszter Vér, Packaging Design Team Leader, Lajos Mezöffy, Senior Sales, Thermoformed Tray and Complete Packaging Solutions, Bálint Tóth, Sales Manager, as well as Design Engineers Bence Botyánszki, Tibor Sós, Vilmos Papp and Adam Jepure.

View the award publication here: https://www.worldstar.org/winners_detail/2601/2022/ 

A high-precision tray solution for automotive headlights

The second WorldStar award was earned for our custom solution in the automotive industry. The goal was to create a thermoformed tray for transporting truck headlights, designed to function within a returnable logistics system using foldable KLT boxes.

Returnable logistics for automotive

The project’s success hinged on achieving a 1/3 return ratio—reducing space requirements and costs while minimizing emissions in the supply chain. Our design incorporated robust raw materials and focused on creating packaging that maximizes efficiency in returnable logistics workflows for automotive applications.

Precision design for automated lines

Engineered for high precision and compatibility with automated production lines, the solution utilized a flexible “card storage system” concept. This ensured reliable protection and optimal use of logistics resources, even in challenging weather conditions.

"The customer set strict requirements for return ratio and automated handling—and we delivered. Meeting all technical and design expectations was a genuine team achievement."
— Rob Hopman, Account Manager Netherlands, and Mihály Adamik, Design Engineer Hungary

“The tray was designed as a card storage system, and it was quite a challenge to meet all the requirements during the designing process, but I’m happy to say that we nailed it!”- explained Mihály Adamik, Design Engineer at Nefab Hungary. 

View the award publication here: https://www.worldstar.org/winners_detail/2657/2022/ 

Learnings and Impact

Sustainability Achievements

Both award-winning solutions highlight Nefab’s core focus on sustainability. By designing trays for circular use and leveraging our GreenCALC tool for data-driven decision-making, we ensure significant CO₂ and waste reductions, supporting more environmentally responsible supply chains.

Operational Efficiency Gains

Our close collaboration with customers leads to packaging that not only conserves resources but also enables lasting operational value. Each solution is optimized for cost savings, compatibility with automated logistics, and efficient material use.

Customer-Centric Design

By prioritizing the unique needs of each client, we deliver packaging solutions that address both immediate and long-term challenges, leading to measurable improvements across key supply chain metrics.

Learn more about our sustainable offerings: 

Nefab’s Thermoformed Trays 

Green innovation and design 

Sustainable solutions