Recyclable Suspension Design for Engineering Actuators
A leading European engineering firm specialising in the manufacture and global distribution of high-precision linear actuators sought to move away from its current “dirty” packaging after receiving negative feedback from EU and UK customers
The Challenge
Both EU and UK customers, including OEMs and integrators in the automation, robotics, and machinery sectors had reported issues with both individual components and bulk orders.
· New packaging design must afford the same or greater protection and Instapak®
· Must be recyclable or environmentally sustainable
· Addresses customer feedback / concerns / issues with current Instapak® solution
· New design should minimise negative feedback and promote a positive brand image.
· Simple and clean to unpack for customers.
· Improve packaging efficiency
· Adaptable to accommodate ad hoc actuator dimensions.
The client required two design solutions for the following product types:
- Single actuators under 3kg, requiring mid-air suspension to avoid vibration and impact
- Multiple actuators shipped in a single carton to reduce costs per unit
Our Solution
1. Single Actuator - Shuriken Suspension Packs
- Configuration: the green suspension design incorporates an inner top and bottom tray which uses a unique and patented die-cut “Shuriken” lattice design, forming a protective suspension framework around the actuator.
- Protection: Superior impact and vibration absorption due to Green Suspension unique 2-ply lattice design.
- Sustainability: 100% recyclable; constructed from FSC solid board and corrugate.
2. Multi - Shuriken Suspension Pack System for Bulk Shipment
- Design: Engineered multi- Shuriken lattice trays that hold multiple actuators in a grid layout, secured in a single carton.
- Features: Die-cut lattices, edge reinforcement, with interlocking Shuriken trays for stacking and pallet shipping.
Instapak® vs Shuriken Lattice Trays: Measurable Benefits
Metric | Instapak® | Shuriken Lattice Trays |
Material Type | PE Foam & Compounds | FSC Solid Board & Corrugate |
Recyclability | Non-recyclable | 100% recyclable |
Setup Time | ~6 mins curing + handling | <2 mins flat-pack assembly |
Unit Cost (average) | Higher | Low/Medium |
Customisation | Mold-dependent | Fully scalable |
Disposal Cost | High - Commercial | Low - Kerbside |
Results & Impact
· Transit damage reduced by 20%
· Packaging cost per unit reduced by 35%
· Eliminates all single-use foam
· Improved customer satisfaction and Brand Image
· Boosted sustainability credentials with buyers and end-users
"We were looking for a packaging solution that aligned with our sustainability goals without compromising protection. The Shuriken Lattice Trays have outperformed expectations—cleaner, greener, and easier to use. The switch from Instapak has saved us time, cost, and reputation."
Ready to solve your packaging challenges?
Let's discuss how we can create a custom solution for your specific needs.
Related Case Studies
Universal AIR|SHIELD™ Packaging for Kitchen Doors
One of the UK’s leading manufacturers bespoke and mass-market kitchen doors, supplying retail, trade, and direct-to-consumer channels. With over 115 unique door SKUs across various finishes—gloss, matte, and solid wood—the client serves showrooms and installers nationwide