100% Recyclable Packaging Eliminates Plastic, Foam Elements | Manufacturing
7/14/2026
RRD’s supply chain expertise, material-sourcing capabilities generate environmentally friendly solution
CHALLENGE
A manufacturer of premium lighting systems wanted to eliminate the plastic elements and polypropylene foam inserts in their lamp packaging. Their intention: Replace the non-biodegradable inserts with a 100%-biodegradable material or other sustainable materials. The materials, though, still had to maintain the required strength parameters, functionality, and initial product protection level.
The manufacturer sought a supplier who could develop, verify, and design a variety of sustainable materials and options. In addition, the supplier had to be capable of sourcing and providing the recommended new sustainable packaging solution.
SOLUTION
As a long-time RRD client, the lighting company was already well aware of RRD’s supply chain management expertise and material-sourcing capabilities.
After conferring with the manufacturer’s production, procurement, and marketing teams to determine their objectives, RRD devised a comprehensive materials strategy. The solution had to align with the zero-plastic goal while simultaneously preventing damage to the lamps during transit. Multiple material options were considered and tested — from paperboard and biodegradable foil to corrugated board, paper fill-outs, and specialized materials that met the requirements.
Ultimately, RRD provided a packaging solution utilizing corrugated honeycomb inserts that provide crush resistance and shock absorption. In addition, RRD sourced and integrated an eco-friendly, FSC®-certified smooth paper that’s lightweight and provides soft wrapping for fragile items. The combination of materials is 100% recyclable and biodegradable, making it ideal for the manufacturer’s packaging needs.
RESULTS
RRD’s comprehensive solution for the lighting packaging sourced materials that were environmentally friendly and could replace the plastic components. Specific results included:
- RRD provided a sustainable and biodegradable solution that retains the product-protection functionality, safeguarding the glass-and-metal product from damage during shipping
- The combination of corrugated honeycomb and lightweight paper is 100% recyclable and biodegradable
- The eco-friendly, smooth paper adds to the product’s premium look, providing a unique consumer unboxing experience
- The solution is cost-efficient, addresses the zero-plastic mandate, and streamlines the overall procurement process