An automotive manufacturer needed a packaging solution that would protect delicate rear door panels. Their current system was inefficient, prone to damage, and not scalable for increasing production volumes.

Key requirements included:

• Precise, protective fit for each unique component.
• Easy identification and access during assembly.
• Scalable for volume production and repeatability.
• Sustainable and cost-effective material use.

Sandland Packaging designed a bespoke corrugated fitment system tailored to fit as many doors as possible. The custom interior packaging kept items secure, separated, and properly supported within the outer box, reducing movement and eliminating the need for plastic inserts.

Our solution included:

• Custom die-cut cardboard fitments for every components
• Layered inserts to separate and protect individual parts
• Lightweight, fully recyclable and carbon neutral corrugated material

The customer saw a marked improvement in both handling efficiency and part protection. Damage during transit was reduced, assembly teams experienced quicker part retrieval, and the packaging aligned with the company’s sustainability targets.

• Zero component damage reported after rollout.
• Faster assembly line processes thanks to better organisation.
• Fully recyclable Carbon Neutral Material meaning our customer can mark their packaging as ZERO emissions on the GHG Scale.
• Scalable packaging design for future production growth.