Universal Packaging Solution for 1U & 2U Server Units
A leading IT hardware distributor specialising in 1U and 2U rack-mounted server units sought a scalable, protective packaging solution for their refurbishment servers for shipping via challenging courier networks (parcels) and palletised movements.
The Challenge
- The client managed multiple server models with varying depths, weights, and connector placements.
- Existing packaging lacked impact protection, leading to transit damage and insurance claims.
- Stockpiling and storing multiple box sizes and foam configuration.
- Sustainability goals called for a reduction in plastic-based materials.
Our Solution
(Hybrid Packaging Approach)
Universal Foam Cradle Design:
- Die-cut PE foam designed to support 1U and 2U formats.
- Design includes slots for Server rack rails
- Recycled content foam (up to 65%) used to meet environmental targets.
Bespoke Carton Range:
- A core set of FEFCO 0201 style cartons, pre-scored to accommodate 1U & 2U depths.
Add-on Protection:
- Corner reinforcement blocks for longer-distance shipping.
Component | Material |
Foam Material | 35% recycled PE, 28 kg/m³ density |
Carton Grade | Double Wall BC Flute (approx. 6mm thick) |
Carton Finish | Kraft outer, test inner (optional print) |
Results & Impact
- Transit damage reduced by 85% across 6-month pilot.
- Rationalise (reduced) packaging SKU’s by 70%, enabling lowered cost-per-pack via efficient tooling and leveraging increased MOQ’s
- Client achieved environmental goals by reducing EPS and increasing recycled content.
- Reusable solution supporting environmental goals and reducing ERP liability.
Summary Benefits:
- Universal & modular system applicable across multiple server types.
- Reduced SKUs and packaging complexity, increased packaging efficiency.
- Enabled co-branded packaging for selected enterprise customers.
- Sustainable design with recyclable board and foam.
- Reusable packaging solution: up to 5 cycles for foam, up to 7 cycles for cartons
Ready to solve your packaging challenges?
Let's discuss how we can create a custom solution for your specific needs.
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