How can you improve product protection while using less material? Discover the story of Sokołów and the innovative DS Smith Safe Tray.

In the FMCG sector, even small improvements can make a significant difference, especially when production volumes run into millions of units. Sokołów faced a challenge shared by many food manufacturers today: how to enhance product protection while optimising packaging costs, without compromising quality.

Starting Point: A Small Change at a Large Scale

The existing trays fulfilled their purpose, but they did not fully leverage the material efficiency or branding potential of the packaging. Occasional issues on the production line and during transportation highlighted opportunities for improvement, particularly in product stabilisation and protection within secondary packaging.

A New Approach: Innovation Through Design

The answer was the DS Smith Safe Tray, an innovative tray whose benefits stem from its carefully engineered geometry. By repositioning fold lines and improving the fit between the packaging and the product, the tray reduces empty space, increases rigidity and distributes loads more efficiently. This made it possible to reduce the material grammage without compromising functionality or aesthetics.

At the same time, the visual appearance was enhanced. The new trays are made from double-sided brown corrugated board (smart brown), reducing the level of material processing required. In addition, the distinctive red Sokołów logo was printed on the front and side panels, strengthening brand visibility.

The design was fully optimised and adapted to the customer's production line, ensuring a seamless implementation.

The Results: Less Material, More Value

The difference was already visible during testing. Products were better stabilised, and the packaging performed its protective function more effectively. However, the true scale of the impact was revealed by the data*:

• Annual CO₂ emissions reduced by 7.48 tonnes (-10.8%)
• 10.8% reduction in material consumption compared with the previous packaging
• Zero plastic

The improved design also delivered:

• Better product stability and fewer damages
• Greater tray rigidity despite lower material grammage
• Easy implementation with no investment required in production lines

Conclusion

The DS Smith Safe Tray demonstrates that true packaging innovation does not always require a revolution. Sometimes, it is a precisely engineered design improvement that unlocks significant value at scale.

With a single solution, Sokołów successfully combined cost reduction, enhanced product protection and stronger brand visibility.

As Agata Szczotka, Brand Manager at Sokołów S.A. summarises:

“The collaboration between Sokołów and DS Smith was smooth and highly collaborative throughout every stage of the project. The implementation of the Safe Tray solution confirms that packaging innovation can simultaneously support business efficiency and environmental goals. The project is an example of a forward-looking approach to packaging design, and its measurable results demonstrate how much can be achieved through shared commitment and effective cooperation.”

This project proves that well-designed packaging can simultaneously improve operational efficiency, enhance brand visibility and provide better product protection.

Methodology

* The CO₂ reduction estimate is based on environmental indicators published by FEFCO (European Federation of Corrugated Board Manufacturers) for 2025. The comparison is based on the annual consumption of the previous packaging versus the annual consumption of the new packaging. The reported value results directly from the reduction in material usage.