The Challenge: End-to-End Plastic Free
The incumbent PE foam generated large volumes of plastic waste and was incompatible with paper recycling streams, preventing alignment with the customer's circularmaterials targets. In addition, the packaging needed to provide reliable protection not only during transport but all the way to the final installation site, without adding complexity to handling or installation processes.
Nefab’s Solution: FiberFlute
Nefab introduced FiberFlute, a paperbased cushioning material engineered to replace plastic foam. Rigorous technical testing demonstrated FiberFlute’s strength and impact resistance, confirming its ability to safeguard the product during transport and handling across the supply chain. The packaging was designed to remain with the product until final installation, ensuring continuous protection, and because FiberFlute is paperbased it can be recycled through established paper waste streams, eliminating the PE foam from disposal flows.
The Results: Improved Sustainability
The new packaging solution resulted in sustainability improvements. Key outcomes included:
- Plastic waste avoided: ~44,000 kg annually by replacing PE foam with FiberFlute.
- Carbon reduction: ~7 tonnes CO₂ saved per year via a lower Packaging Carbon Footprint.
- Protection maintained or improved: Product integrity preserved throughout transport and final installation.
- Recyclability: Packaging can be processed through established paper waste streams, eliminating PE from disposal flows.
- Business impact: Enables the customer to meet sustainability targets while preserving supply chain performance.
Take the Next Step
Switch to high-performance, recyclable fiber packaging today. Our FiberFlute solution helped a global telecom leader avoid 44,000 kg of plastic waste annually while ensuring total product safety from transport to installation. We can help you achieve similar results.
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