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Corrugated Monitor Packaging

The corrugated monitor packaging, developed for GE HealthCare’s CARESCAPE Canvas™ patient monitors, provides sustainable and protective transit for high-value glass displays. This innovative, plastic free packaging solution reduces environmental impact while offering a seamless user experience.

The Challenge

GE HealthCare encountered a typical challenge in shipping high-end medical devices — securing packaging that safeguards their delicate monitors during worldwide transport, while considering the environmental impact and enhancing the unboxing experience. The original packaging for the CARESCAPE Canvas Monitor used conventional cardboard boxes with PE foam cushions. GE HealthCare collaborated with Nefab to create an improved packaging solution.

Nefab's Solution

Nefab proposed a corrugated packaging solution with multiple custom inserts designed to fully protect the customer’s product. After several design iterations and close collaboration with the customer, a mutually acceptable solution was reached. The final design successfully combines sustainability and functionality, reflecting Nefab’s commitment to resource efficiency by maximizing material use and reducing costs. Highlights of the solution include:

  • The solution was developed through a continuous improvement process that included rapid prototyping and practical testing with functional products. It features an outer box, an inner sleeve, and strategically placed inserts for optimal protection and an intuitive unboxing experience.
  • Every inch of the packaging is now fully utilized, unlike the previous solution where the PE foam meant shipping excess air with the product.
  • With a streamlined design, the customer can now ship more products at once, optimizing their supply chain.
“Shipping a huge, high-value glass screen without layers of protective foam might seem unthinkable. That’s exactly what GE HealthCare and Nefab have achieved with this packaging solution. Designed specifically for CARESCAPE Canvas patient monitors, this plastic-free packaging defies expectations by offering sufficient protection without traditional plastic cushioning materials,”
said Erik Tigerstedt, Lean Manufacturing Leader for Patient Care Solutions, GE HealthCare

The Results

The new packaging design provided many environmental and economic advantages. Key outcomes include:

  • Eco-Friendly Design: A plastic-free, mono-material solution that reduces package size by 34%, resulting in a 23% reduction in CO2 eq and 25% less landfill waste.
  • Cost-Effectiveness: Achieved a 66% increase in packing speed while lowering total costs by 46%.
  • Enhanced Protection: Successfully passed the ISTA 2A test, securing the sensitive glass displays in place during transit.
    • Logistical Efficiency: Improved space utilization allows for 50% more products to be transported, reducing transportation costs.
    • Reduced Emissions: Achieves a reduction of 211 tons in CO2 emissions annually, contributing to emission reduction efforts.

 

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