What was the challenge?
Service Robotics Ltd, a provider of remote care technology for health and social care, faced a challenge in reducing its material usage, storage space, and unboxing experience to one that was exciting and easy to access.
The current packaging resulted in bigger office space requirements and a poor adoption rate of the technology, as the unboxing experience was overwhelming. The original box featured plastic handles that wore out quickly and a plastic insert that was difficult to remove neither practical nor welcoming for end users receiving the robot in their homes.
Results: What the new packaging achieved
Service Robotics Ltd collaborated with Forever Green Packaging to enhance their packaging into a more suitable, eco-friendly, and customer-oriented solution. After analysing the current unboxing experience with real users, the team replaced the large cardboard box with a user-friendly, home-like packaging design built from a single material. Here is a breakdown of each result area.
1. Space Efficiency
A smaller packaging solution was introduced that can be easily stored and folded when not in use. A comparison between the old and new boxes showed that the new solution led to a remarkable 25% space saving when boxed and an outstanding 97% saving when folded flat.
This means that using the new packaging led to significant cost savings in storage and a more organised inventory management system particularly valuable for a health and social care technology provider managing stock across multiple sites.
Key result: 25% space saving when boxed; 97% saving when folded.
Impact: Reduced storage requirements and lower inventory management overhead.
View our protective packaging solutions →
2. Eco-Friendly Advancements
The new packaging used by Service Robotics Ltd not only helped the company become more efficient but also aligned with its commitment to sustainability and B-Corp goals. By eliminating the need for excess plastic, the company was able to drastically reduce its environmental footprint.
The box was designed to be durable and reused, contributing to a greener planet by reducing packaging waste. FGP's aim is always to reduce or remove plastic as much as possible and while plastic can in some contexts be considered the more environmentally friendly material due to its functionality and Life Cycle Analysis, the plastic-free mono-material solution introduced here enhanced both the box design and its recyclability.
Key result: 100% reduction in plastic usage across the packaging.
Impact: Single-material (cardboard only) packaging easy to recycle, aligned with B-Corp goals.
Learn about our sustainability commitments →
3. Streamlined Unboxing Experience
The new packaging provided more than just space savings it simplified the unboxing process significantly. Employees at Service Robotics Ltd discovered that the new unboxing experience excited users, particularly those who were anxious about introducing new technology into their homes.
It was faster to unpack than traditional boxes, and the open face of the packaging further delighted users, increasing their adoption of the robot. Turning a potentially intimidating moment into a welcoming one had a direct impact on the business's core mission.
Key result: 70% quicker pack and unpack times versus the previous method.
Impact: Higher technology adoption rates among end users; reduced anxiety around the product.
View our paper void fill systems →
4. Reducing Plastic
In the original box, there was a large plastic insert that took up unnecessary space and wasted material. Additionally, the handle was problematic as it tended to break easily, creating both a quality issue and additional waste.
The objective was to switch to a new design that used no plastic at all, improving its environmental impact and simplifying the recycling process for end users. By using a single material cardboard in its production, the new packaging is not only easy to use but also easy to recycle at the end of its life.
Key result: All plastic components eliminated from the packaging design.
Impact: Improved environmental credentials; simpler end-of-life recycling for customers..
See our guide to eco-friendly packaging →
5. Adaptable For Growth
Service Robotics Ltd anticipated a new design for their robot and created a box that could easily be modified to accommodate it. This was achieved by simply replacing an insert a low-cost and simple amendment that required no new box tooling or investment.
This forward-thinking approach prevented them from discarding boxes that were no longer useful and saved money in the process. The packaging was designed not just for today's product, but for the company's growth.
Key result: Packaging adaptable to new product designs via simple insert swap.
Impact: Avoided box obsolescence; protected packaging investment as the product evolves.