Cookware Company Deploys 100% Recyclable, Mono-Material Packaging | Manufacturing
12/17/2025
RRD’s sustainable, paper-based packaging solution provides premium quality, cost-efficiency for growing brand
CHALLENGE
A rapidly growing cookware company continuously sought better solutions in two key areas: speed-to-market and cost efficiency.
As the company expanded their retail presence, they also introduced more cookware sets of varying sizes and compositions. Consequently, they required a partner capable of simplifying packaging design using mono-material (packaging made from a single type of material). The ideal partner would also be able to support faster product launches, provide sustainable, premium quality packaging, and lower overall costs.
SOLUTION
RRD Asia, a partner with the cookware company for the past several years, developed a mono-material packaging solution that achieved simplicity and recyclability. The solution, covering a diverse range of cookware with the largest sets weighing up to 23 kg (approximately 51 lbs), also met the client’s cost and timeline objectives.
In support of the rollout, RRD implemented a collaborative packaging-optimization program that incorporated superior design, efficient project management, and responsive technical support. Key initiatives included:
Design upgrade: RRD utilized 100%-recyclable, paper-based materials across all components and streamlined structural designs to enhance the brand’s consistency and recyclability.
Cost efficiency: Through smart material utilization, RRD was able to reduce overall material consumption — repurposing offcuts from other components — to lower production costs without sacrificing structural integrity or aesthetics.
Rapid project turnaround: The entire project cycle, from customer specification to first shipment, was completed within four weeks. Biweekly coordination meetings between RRD and the company’s design and sourcing teams ensured the project stayed on track throughout the process. Daily progress was driven by calls and video discussions on the various design details, with same-day visual reviews keeping the project in motion.
Detailed documentation, assembly procedures: RRD produced and delivered detailed FATP (final assembly, test, and pack) documentation and assembly SOPs (standard operating procedures). These were presented as comprehensive visual assembly work instructions — clearly outlining every step of the process to ensure smooth execution by the contract manufacturer.
RESULTS
RRD? Asia's ability to implement ?an innovative and comprehensive packaging program ?comprising high-quality design, project? management, and technical? support? elements resulted in:
- Business growth: The client secured a new order from a leading international supermarket chain, significantly boosting overall sales volume
- Cost efficiency: Through smart design optimization, RRD achieved meaningful cost reductions while preserving the brand’s premium presentation and quality standards
- Sustainability: All display packaging was transitioned to 100%-recyclable, paper-based mono-material, aligning with circular economy principles
- Partnership expansion: The client recognized RRD’s reliable support and efficiency, further strengthening the partnership and paving the way for new projects