Europe’s leading paper-based packaging manufacturer Smurfit Kappa has developed a new solid board division which uses less packaging material, improves the end-of-line packaging process, lowers the risk of transit damage, plus improves the economy and environmental impact of the supply chain.

The new Triangular Solid Board Division has been created by Smurfit Kappa Lokfast for Diageo’s drinks brand ‘Dimple’. This product has an irregular triangular bottle shape which posed a number of design considerations.

Traditional divisions - using multiple solid board strip sizes for square cells – would have resulted in wasted spaces between Dimple’s triangular bottles.

The Triangular Solid Board Division’s design uses only three solid board strips – for a snug fitting triangular division. Resulting economical and environmental benefits have been:

• A reduction in the outer case size by 16%
• Approximately 9% less material being used to manufacture both the division and the case
• 10% more cases being packed onto a pallet and into a container

The Triangular Solid Board Division has been designed to protect products using restraint – as opposed to alternative cushioning methods.  The tighter the pack the more minimised the movement in transit – which has lowered the risk of damage and enabled the product to arrive with retailers in excellent condition.

Unlike previous designs – which tend to collapse within a case during the bottling line insertion and packing process - the Triangular Solid Board Division’s unique design ensures it remains open and securely in position. This means packers can devote their full attention to placing bottles into cases without having to rearrange divisions. This reduces the risk of potential label damage. As a result, production output and efficiencies can be maintained and increased.

The Triangular Solid Board Division is manufactured and assembled by Smurfit Kappa Lokfast before being transported to customers for end use. Its symmetrical folding action allows it to be flat packed for maximum packing and transport efficiency – then re-opened for insertion into cases with maximum ease and minimum fuss.

Compliant to retailer requirements, the Triangular Solid Board Division is made from 100% recyclable solid board material, uses no mixed materials and is fully biodegradable and recyclable.

Phil Dyer, Sales Director at Smurfit Kappa Lokfast said: “Because of the shape and size of the Dimple bottle, the use of traditional square divisions would have resulted in wasted space. “

“Our development of the Triangular Solid Board Division provides a unique packaging solution for a unique product. It achieves environmental and economical savings by reducing unused case space, decreasing the size of the outer case and the amount of material used, plus increasing the number of cases per pallet. The tighter packing design also means that the product is fully protected through the supply chain to ensure it reaches consumers in peak condition.

“All combined, this has helped Diageo to reduce transport breakages, emissions and costs.”

For more information on Smurfit Kappa Lokfast’s solid board divisions, contact Phil Dyer on 07801 316 426 or email enquiries@smurfitkappa.co.uk or visit www.smurfitkappa.co.uk