TipToi Cardboard Fitments| Alternative to plastic inserts | Smurfit Kappa
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SUCCESS STORY

Helping TipToi switch from plastic to paper-based inserts, saving 162 tonnes of CO2 emissions

The Challenge

A leading German company in games, puzzles, and toys, offers the TipToi brand, an interactive pen and book set that educates children using modern technology. The packaging previously included a plastic insert to hold components, but Ravensburger aimed to replace this with a more sustainable alternative.

The Approach

Our expert designers developed the first insert with a sloping wall to securely hold the electronic pen and a cushioned fold to protect the tip. The second insert was crafted to cushion the book, ensuring both fit neatly into the outer box. The design was then drop and transit tested to ensure performance throughout the supply chain.

The Result

By switching to paper-based inserts, the TipToi brand has reduced CO2 emissions by 162 tonnes annually. Of this, 52 tonnes come from eliminating plastic, while 110 tonnes are saved through transport optimisation, as the flat-packed design requires 63% fewer trucks. The solution also improves warehouse efficiency, saving over 100 pallet spaces.

Winner at the OBAL ROKU 2024 Czech Packaging Awards

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