DS Smith: Sustainable Packaging Collaboration at its Finest

DS Smith is once again showing how it is leading the way as a provider of sustainable and fibre-based packaging solutions.

The business is working with Mondelēz International, one of the world’s largest snacking companies, to trial 300,000 Cadbury Heroes paper tubs across Tesco stores across the UK.

It follows years of R&D and is the second sustainable packaging initiative from Mondelēz and Tesco, which recently worked together on a trial to introduce ~1.8 million Cadbury Crunchie multipacks with 60% less outer plastic packaging per pack compared to a standard multipack format, thanks to an innovative sticker solution.

Joanna Dias, Mondelēz UK Sustainability Lead, comments: "We are extremely proud to announce the new Cadbury Heroes paper tubs and are excited to hear consumer feedback on the new packaging.

"The paper tubs demonstrate once more Mondelēz's commitment to driving sustainable packaging solutions. This test-and-learn initiative in partnership with Tesco will help inform our long-term efforts to reduce virgin plastic.”

Pack Light and Right

The Cadbury Heroes initiative represents the latest step in Mondelēz’s global 'Pack Light and Right' strategy, which focuses on evolving packaging so that it is recyclable, utilising recycled materials where appropriate and improving recycling infrastructure and capabilities.

Paul Clarke, UK & Ireland Managing Director of DS Smith, adds: “This project showcases our close collaboration with Mondelēz International to deliver more innovative packaging in response to growing consumer demand for sustainable solutions that make a positive impact.

"It demonstrates how we can design out waste without compromising on quality or design – from the rounded corners for enhanced shelf appeal and high-quality print that supports standout branding.”

DS Smith's Now and Next strategy helps customers to design out waste. Over the past five years, the company has removed more than 1.7 billion pieces of plastic – exceeding its target by more than 700,000.

DS Smith has also developed Circular Design Metrics – an industry first – to rate and compare the circularity of packaging designs, keeping materials and products in use for longer. 

DS Smith works alongside many of the world's best-known FMCG brands. Since 2020, the company has replaced more than a billion everyday plastic items from supermarket shelves, including fruit and vegetable punnets, plastic carriers and shrink wrap found on soft drink bottles.

This new solution for packaging is made up of a robust side panel that consists of a double wall of corrugated cardboard.

DS Smith designed sturdy side caps and end-based protective buffers to ensure a protective barrier is in place on each side of their packaging shape and structure.

Space-saving innovation transforms efficiency

Elsewhere, DS Smith is working with Dynamic Logistic Systems' (DLS) on corrugated cardboard buffers, specifically intended to provide optimal protection for its industrial products against shocks and vibrations during transportation to customers in local and international destinations.

The new DS Smith packaging solution is estimated to take up around 60% less space during storage and transportation compared to previous DLS packaging solutions used by the company.

William Lieftink, Managing Director, Dynamic Logistic Systems (DLS), says: "The space saving benefits are extremely impressive. We now need far less storage for our packaging materials, and this reduces our need to move pallets and products around.

"This also lowers the risk of damage to products during the value chain, and the fibre-based materials are aligned with our sustainability objectives.

"We are keen to optimise our supply chain processes wherever possible and provide a best-in-class service to customers."

DS Smith's packaging design has boosted warehouse capacity for storing semi-finished machine parts and accommodating new orders during busy periods.

The new packaging stacks more efficiently, and its fully recyclable fibre-based materials provide an effective, space-saving solution that replaces the company's former reliance on Expanded Polystyrene Foam (EPS) buffers while supporting sustainability goals.

Remko Berkhout, Marketing and Communications Manager for Benelux at DS Smith, adds: "We used our expertise in sustainable and fibre-based packaging design to support DLS in moving towards a more circular future. Our packaging design is helping to optimise their supply chain to benefit the company's customers in a variety of sectors.

"Vital machine parts such as dispensers for conveyor systems can now be stored and transported with increased efficiency and we are providing an alternative to previous plastic-based options.

"We are committed to helping our customers meet their sustainability objectives with bespoke packaging solutions."

DLS collaborates with clients across multiple industries to address the rapidly evolving demands of supply chain operations and delivery.

As a specialist in intralogistics subsystems for internal material handling, the company offers solutions ranging from gravity rollers to fully automated order picking systems, including smart conveyors, shipping buffers, pallet handling, sortation and order picking and closing technologies.

DS Smith is dedicated to driving an industry-wide shift towards a circular economy by delivering sustainable solutions to customers in thirty-four countries globally. It pursues a target-driven sustainability strategy that supports its mission: Redefining Packaging for a Changing World.