Car Headlight Packaging | Case Study | Smurfit Kappa
Automotive Packaging


Our sustainably designed packaging for car headlights led to 30% reduction in both cost and material

The Challenge
Our customer was looking to improve their existing pack for headlight covers. The current pack was effective as it protected the contents from all directions but this meant that the amount of corrugated material used was quite large. The headlight covers however did not require so much protection as they never fall on their top side so there was an opportunity to reduce the insert size.
Automotive Packaging, Car Parts Packaging
Automotive Packaging, Car Parts Packaging
The Approach
Working closely with our customer we launched a packaging redesign project to remove the safety risk and simplify the existing packaging.  The new universal left and right-hand insert is made of kraft BC-flute and creates a solid frame for the pack. The headlight cover is now only fixed at the back and large void zones prevent the sensitive lens and fragile grips from damage. 
Automotive Packaging, Car Parts Packaging
The Result
While maintaining sufficient protection, the amount of material was reduced by 33% and we reduced the packing time by 38%. We applied this principle to five different headlights and achieved an overall cost saving of 34% for our customer.
Automotive Packaging, Car Parts Packaging

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