The European Packaging Regulation PPWR (Packaging and Packaging Waste Regulation) introduces new requirements along the entire supply chain. The aim is to avoid packaging waste, better reuse materials, and significantly increase the proportion of recyclable and bio-based materials. For many companies, this means rethinking existing packaging solutions, adjusting processes, and finding alternatives.
The Coplax Verpackungen AG from Zug presents practical solutions with five current customer examples, demonstrating how demanding packaging tasks can be solved sustainably and efficiently. The company focuses on cardboard instead of plastic and combines robust materials with intelligent design. The main goal is to create functional packaging that meets both ecological and economic requirements.
Modular Cardboard Solution with Corrosion Protection
An automotive supplier was looking for a packaging solution for a newly developed machine part that is sensitive to abrasion and corrosion. The requirements included high product protection, environmental compatibility, cost efficiency, maximum space utilization, and suitability for automated filling by robots. Coplax developed a reusable transport packaging made of corrugated board and gray cardboard in close coordination with the customer. The solution is stackable and features removable single-use grid compartments that can be flexibly adapted to different part sizes. Elements made of VCI corrosion protection paper were integrated for protection against corrosion. An ultra-thin PE film minimizes potential abrasion, while a sealed aluminum composite hood reliably protects the component from moisture during storage and transport.
The result is a sophisticated, modular packaging solution that combines high protection with sustainable materials and process-optimized handling.
Cardboard Euroboxes as an Alternative to KLT Containers Made of Plastic
A company in the mechanical engineering and plant construction industry was looking for a sustainable solution for storing and keeping small parts, individual parts, and semi-finished products. The goal was to replace the previously used plastic Euroboxes with a more environmentally friendly variant made of cardboard—without compromising on key requirements like stability, transport security, and stackability. The new solution should also be more cost-effective and integrate smoothly into existing logistics and handling processes, as cardboard and plastic boxes were to be used in parallel. Coplax then developed a packaging solution from single and double-walled corrugated cardboard in four standardized sizes. A special design feature is the so-called "double bottom": an additional cardboard layer on the underside of the box fits exactly into the opening of the box below, preventing slipping when stacking—even in mixed operation with conventional plastic containers. Practical handles also facilitate handling. The entirely cardboard packaging can be easily disposed of in waste paper after use and does not require elaborate cleaning measures like plastic containers. The solution combines sustainability with functionality and integrates seamlessly into existing workflows.
Mono-material Solution Made of Block-glued Cardboard Replaces Cardboard Foam Packaging
An internationally active manufacturer of electronic production equipment sought an
environmentally friendly and more economical packaging solution for sensitive parts, which were previously packaged in a combination of cardboard and foam. The goal was to develop a mono-material solution that does not compromise on product protection. The biggest challenge was to replace the protective properties of the flexible foam with a dimensionally stable cardboard solution. Coplax then developed custom-fitted, block-glued cardboard molded parts made of solid corrugated cardboard. This single-material solution is characterized by high compression and impact resistance while being lightweight. This facilitates handling, shortens packing times, and reduces both material and disposal costs. To ensure optimal fit, developers relied on CAD-supported prototype creation and tested the packaging directly on-site with the customer.
Cardboard Packaging with an Unboxing Experience
A garden center with an affiliated online shop was looking for a sustainable and functional packaging solution for shipping flower bouquets and potted plants. The requirements included reliable product protection and transport security, as well as user-friendly handling and an aesthetically pleasing appearance. Coplax then developed a packaging that combines a sturdy shipping box with a flexible folding cardboard insert. This securely fixes different plant formats and ensures an attractive presentation. An integrated tear strip allows for easy opening, and the complete cardboard construction is recyclable. Thanks to a well-thought-out implementation, the usual tooling costs for the tear perforation were eliminated. The flat delivery of the boxes and inserts
saves storage space and reduces logistical effort. The packaging process was also optimized and made efficient. The desired brand image was implemented with high-quality, multi-colored printing, resulting in a convincing unboxing experience.
Fruit and Vegetable Tray Made of Cardboard
A Swiss producer of organic fruits and vegetables needed a sustainable packaging solution that is both functional and moisture-resistant, while maintaining the freshness and quality of delicate products until sale in the supermarket. The packaging needed to be robust, food-safe, and flexibly tailored to different product types. Additionally, it was necessary to consider seasonal fluctuations, individual printing requests, and highly varying order quantities from buyers. Due to the company's ecological focus, only a cardboard solution was considered. Coplax then developed a food-safe cardboard tray with an environmentally friendly lacquer coating that protects against moisture and can be fully disposed of through the waste paper cycle. In close collaboration with the customer and based on intensive product tests, a packaging was created that meets the complex requirements. A carefully tailored production and delivery plan ensures timely provision in appropriate quantities—without delays in the supply chain. The result is an economically and ecologically sustainable solution, now also extending to other product areas of the company.
The five cases exemplify how sustainable packaging solutions made of cardboard are already a reality today—and how companies can actively and successfully meet the challenges of the
