Emergency exit signs packaged in lighter, recyclable cardboard

Priory Direct claims STG Aerospace's emergency exit sign products are packaged in "100%" recyclable cardboard, optimising material use and cutting weight and costs in half.

STG's "world's first sustainable" emergency floor path sign system is shipped internationally, so its packaging must protect large volumes of product during transport and long-term storage, while complying with local regulations and standards, as well as those of the aerospace industry.

The floor path sign itself measures two metres in length and 11mm in width, described as an "awkward packaging shape". Oversized packaging requires more fill material, takes up more space in transport, and increases the overall weight of the shipment, all of which raises the cost and environmental footprint of the packaging.

Ryan Vincent, Production Design Engineer and packaging redesign project lead at STG, explained: "We had a packaging solution for our existing range of floor path signs which were of the same dimensions. A review highlighted the need to improve its environmental impact which was inconsistent with the purpose of our new eco product. The packaging came in long, heavy cylindrical tubes made from cardboard with a layer of plastic reinforcement on top and plastic caps on the ends. The tubes were over an inch thick and had a large diameter, weighing around 7kg or 8kg empty. It was clear that we needed to find a more sustainable packaging solution for the new eco product, however it still needed to be strong enough to keep our product safe and secure."

Gordon, Sustainable Packaging Consultant at Priory Direct Leer continued: "Our first solution was to fold a flat cardboard package around the product to make it sturdy and also stop it rolling, and we also proposed a telescoping box option where two separate parts would fit snugly together. However, due to STG's unique requirements, neither was suitable, so we reverted to a cylindrical tube shape, which significantly reduced the volume of material used and the environmental footprint. It's a useful reminder that sometimes it's not about reinventing a design, but rather working to optimise an existing solution as much as possible. While from a commercial perspective this means we're 'selling' less material, we're supporting our customers in reducing the environmental impact of their packaging, which is our fundamental mission as an organisation. It was refreshing to work with STG because we were designing a solution with limited information, and STG sent us detailed drawings and the specifications that needed to be met, which made it easier for us to be precise."

After testing a wide range of solutions, STG and Priory Direct came up with the current one, which reportedly reduces the weight of the package from 8kg to 4kg. It is said to be plastic-free and designed to align with environmental standard ISO 14001 and reduce the administrative burden of international packaging regulations.

Ryan added: "Recyclability is important to us because we can't control what happens to our packaging once it leaves our warehouse, by ensuring it is 100% recyclable we know that wherever it ends up, even in landfill, it will eventually break down, just like the eco-friendly products it was designed to protect. Because this packaging is so much better for the planet and our budget, we have switched our entire range of floor path signage to sustainable packaging."

Priory Direct continues to work with STG to provide alternative packaging solutions for its range of LED cabin lighting systems.

Other redesigned paperboard packaging includes Akarton's Hexpand packaging, which is designed to protect fragile items such as electronics, lighting fixtures and spare parts in transit while being easily recyclable; and Mondi's custom fibre-based boxes for Zwiesel Glass' mouth-blown glassware, designed to keep the product intact while creating a 'premium' unboxing experience.