Polypropylene Box with Inner Cut-outs is used to Safely Transport and Protect Automotive Car Lamp Units to Final Assembly Manufacturing Plants

Polypropylene packaging with inner cut-outs hold lamp units in place while in transit, reducing the need of additional protective packaging material.


A Slovak automotive car-parts manufacturer, specialized in automotive lighting, was looking for a reusable and cost-effective electrostatic discharge (ESD) packaging solution to protect and transport lamp units to their final assembly manufacturing plants. The boxes needed to be foldable and easy to store following the delivery of the car lamps to assist in space saving when in return transit to the manufacturer.

Our solution:

DS Smith Plastics in Hurbanovo, Slovakia designed a polypropylene packaging box system consisting of a multi-way die cut inner box that firmly holds the automotive lamp unit in place during transit. The cut-outs replaced the need for additional protective packaging materials, thus reducing overall packaging costs. The boxes are then easily foldable to be returned to the auto parts manufacturer, and  easily popped back into position  to be reused in another transport of car lamps. The polypropylene boxes are lightweight, stackable, reusable and can be recycled at the end of its useful life.


The autoparts manufacturer required DS Smith Plastics to make a multi-use, collapsible solution for car lamps with a life span of up to six years. The polypropylene packaging box system meets these requirements. Additionally, the custom design of  this reusable packaging system reduces the need for additional protective packaging materials.  The polypropylene is safe for electro sensitive products, preventing any kind of surge electronic products may face. The foldable containers can be reused over and over again, and are easily stored because of their foldability and stackability, making them the ideal product for transporting car parts to manufacturers.

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