How Abrasive Protection Keeps Telecom Equipment Reliable

According to GSMA¹, by 2024 mobile internet was already used by 58% of the world’s population, supporting 24 million jobs worldwide. In that same year alone, 200 million people went online for the first time. By the end of 2025, the number of mobile internet users is expected to approach 5 billion.

With so much of the world depending on seamless connectivity, even a brief disruption can send shockwaves through entire economies and societies. When networks go down, the ripple effects are immediate and severe. Take the power outage across Spain and Portugal in April 2025². Trains stopped mid-journey, payments froze, and mobile networks collapsed. Moments like these remind us how critical it is to protect and maintain telecommunications infrastructure, because reliability starts not just with networks, but with the equipment that supports them.

PwC projects that by 2028, 5G will power close to two-thirds of global mobile connections. (Source: Global Telecoms Outlook 2024-2028)

Abrasion: A Small Problem with Big Consequences

Telecom equipment is as sensitive as it is essential. Sensitive or painted surfaces like screens, lenses or polished metal components in telecom equipment are highly prone to scratches, and micro-damage. Abrasion happens when friction, vibration, or environmental stress wears down protective layers. Once the surface is compromised, internal components are exposed, leading to:

• Signal disruptions
• Reduced performance
• Equipment failure and costly downtime

When protected against abrasion, equipment is not only safer in transit but also more reliable over its entire lifespan. That reliability is what keeps billions of people connected every single day.

Designing Smarter Cushioning Solutions for Sensitive Equipment

Effective cushioning, an additional layer between the product and the packaging, must be tailored to the sensitivity of the product, the shipping conditions it will face, and what happens when the packaging reaches end-of-life. Recyclability, biodegradability, and disposal options are now just as important as protective performance.

A well-designed cushioning system prevents direct contact between delicate surfaces and packaging. It serves three purposes:

1. Reducing friction that leads to scratches.
2. Absorbing shocks and vibrations during transit.
3. Preserving the pristine finish of sensitive components.

New Anti-Abrasion Cushioning Alternatives

One of the most effective solutions emerging today is fiber-based cushioning with an anti-abrasive coating. Made from natural fibers, this material is soft enough to shield delicate surfaces by absorbing shocks and vibrations during transport. The anti-abrasive layer ensures that sensitive components arrive without surface damage, eliminating the need for additional plastic film or bags. Just as important, fiber-based inserts are recyclable, lightweight, and perform well in different shipping conditions, making them a practical choice for protecting telecom hardware.

Tests comparing polyethylene foam and Nefab’s FiberFlute showed that FiberFlute provides 40–45% better shock absorption, meaning less material is needed to protect products. (Source: Nefab)

Another material being explored is bio-based foam cushioning, made from renewable resources such as starch or algae. These foams mimic the protective qualities of plastics but with less environmental impact. While still at an earlier stage of adoption, they show potential for future applications.

Case in Point: Fiber Cushioning for Remote Radio Units

A good example of abrasive protection in action comes from one of the world’s largest telecom equipment manufacturers. The company needed a way to protect its Remote Radio Units (RRUs) during shipping while moving away from single-use plastics.

Working in partnership with Nefab, the company transitioned to fiber-based packaging inserts with a special anti-abrasion coating. This coating protects delicate surfaces from scratches during transport, eliminating the need for additional plastic bags around each unit. The inserts are durable and capable of withstanding loads of up to 36 kilograms without compromising on product safety, packaging quality, or functionality.

The switch delivered measurable results:

• Plastic reduction: total plastic content fell from 20% to less than 1%.
• Optimized design: packaging size decreased by 15–20% compared to conventional plastic inserts.
• Sustainability gains: fully recyclable materials replaced plastics while still delivering the same high standard of protection.
• This case proves it’s possible to combine abrasive protection, sustainability, and efficiency, setting a clear path forward for protecting sensitive equipment without unnecessary environmental impact

Fiber-based, anti-abrasive packaging inserts safeguard sensitive telecom equipment while cutting plastic from 20% to less than 1% and reducing packaging size by up to 20%. 

The Bigger Picture

In the end, protecting telecom equipment from damage is about more than preserving hardware, it’s about safeguarding the future of communication. 

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