One year after implementing a major packaging overhaul, Dutch online drugstore Plein.nl and DS Smith have achieved significant sustainability and operational improvements.
The collaboration eliminated 20,900 cubic meters of empty space annually during shipping, cut 9,200 kilograms of plastic filler and reduced product damage by 25%, down from more than 5,000 leak incidents per year.
The project centred on installing two automated packing machines and redesigning corrugated packaging to better fit the retailer’s product mix. The machines now handle 98% of all orders, improving efficiency and reducing breakage linked to oversized boxes.
Sustainable and Efficient Packaging
Key upgrades included switching to 100% recycled brown corrugated cardboard, using R-flute board, redesigning artwork to minimize ink and improving lid perforations. These changes save 30% warehouse space, reduce CO₂ emissions and cut forklift and pallet requirements.
Patrick van den Bosch, Logistics Manager at Plein.nl, said the automation project has improved internal logistics by reducing manual handling and simplifying the packaging process.
Customer Satisfaction and Damage Reduction
Previously, Plein.nl used box sizes that no longer fit its changing product range, leading to excess plastic and customer complaints. According to Marketing Manager Janneke Bongartz, the redesign has improved the customer experience by reducing oversized packaging and eliminating plastic fillers.
Despite detergent sales doubling, damage rates are down 25%, reducing waste and customer service interventions.
Optimizing for the Entire Supply Chain
DS Smith Sales, Marketing and Innovation Director Hiddo van de Ven noted that the project shows how incremental sustainability improvements can reduce waste, streamline logistics and improve the end-user experience.
Plein.nl and DS Smith say the project has laid the foundation for further upgrades and sustainability initiatives.
DS Smith is a global provider of fibre-based packaging solutions and operates across packaging, paper and recycling. The company focuses on circular design and works with customers in retail, consumer goods and industrial markets to reduce waste and improve sustainability in supply chains.
Source: DS Smith
