Award-winning packaging for big bottles | Smurfit Westrock
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10L bottle packaging

SUCCESS STORY

Award-winning packaging for big bottles: Cutting costs and carbon

The Challenge
The customer needed a packaging solution that would prevent pallet collapse during transport without adding complexity, excess material or handling time. Existing designs relied on heavy board grades, multiple support columns and inefficient packing processes that increased costs, storage demands and the risk of load failure.
Packaging for 10L Bottles
Packaging for 10L Bottles on a pallet
The Approach
Smurfit Westrock developed the Hol(e)y Tray, a smartly engineered divider featuring precision-cut holes that allow 10-liter bottles to interlock and stabilize one another on the pallet. The design enabled a shift from BC to thinner EB flute, simplified the overall structure, and reduced internal supports from six square columns to four rectangular corner columns, improving transport stability while cutting material use. Thinner dividers also optimized warehouse storage and reduced empty packaging transport.
Packaging for 10L Bottles on a pallet
The Result
The new solution delivered a stronger, more stable pallet while cutting handling steps by 27% and packaging costs by 9.1%, generating annual savings of €69,300. Warehouse space needs dropped 40%, eliminating 13 truck trips a year. Material and transport efficiencies cut the customer’s carbon footprint by 43 tons of CO₂. With no collapsed-load complaints and improved ergonomics through automation, the Hol(e)y Tray shows how smarter design can boost performance, efficiency and sustainability.
Packaging for 10L Bottles Stacked
WorldStar-Logo-2026

Winner at the 2026 WorldStar Awards

WorldStar-Logo-2026

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