Mono-Material Packaging for Carbon Brake Discs

The Challenge: Intuitive and Cost-Optimized Packaging for Carbon Brake Discs in Air Freight

The customer launched a new product line of carbon brake discs for race cars. With no previous packaging solution as reference, Nefab needed to prevent potential issues through smart, intuitive design. This design needed to meet requirements such as:

• Intuitive packing process: All components needed to fit properly in each box with clear handling procedures for workers
• Precise positioning: Brake disks required exact orientation to prevent damage during transit
• Cost optimization: Air freight from Europe to Asia demanded minimal shipping volume and weight

Solution: Innovative Mono-Material Packaging

The packaging partner delivered a revolutionary mono-material approach using 100% corrugated materials for both outer and inner packaging components that simplified the recycling flow for end users. This innovative solution was also both lightweight and foldable for efficient storage and transport.

Results: Environmental, Operational, and Strategic Gains

The customer achieved significant improvements across multiple performance metrics. Benefits of this solution included:

• Environmental Impact: 36% CO2 savings annually compared to standard multi-material solutions, and 100% recyclable packaging through single waste stream
• Operational Benefits: Optimal storage conditions through flat-packed design, reduced air freight costs via weight and volume optimization, streamlined logistics with annual bulk delivery, and enhanced worker efficiency through intuitive packing process
• Strategic Advantages: This scalable solution provides an adaptable framework for future product lines

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Additional Resources

• Optimized Fiber Solutions: Learn more about our complete range of fiber-based packaging solutions.
• GreenCalc: Use our certified calculator to measure potential financial and environmental savings.
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