Mondi, a global leader in packaging and paper, has developed an optimised packaging concept for the water heater range of its long-standing customer Stiebel Eltron. By reducing the number of different corrugated board grades by more than 75% while maintaining optimal product protection, the solution simplifies the packaging system and enables flexibility for different market requirements through digital printing.
Managing a wide range of packaging designs and materials can increase complexity across procurement, production and logistics. With 150 packaging variants in use, Stiebel Eltron sought to refine its packaging portfolio as part of a broader redesign. This included converting four-colour printed designs to a modern design using white digital printing on brown corrugated board, creating a consistent look across the product range.
Mondi analysed the existing corrugated packaging solutions and grouped them according to product weight and transport requirements. This enabled the identification of the most suitable brown corrugated board grade for each product group, creating a more structured portfolio.
White digital printing supports the harmonised packaging concept, enabling multiple designs and print volumes to be produced on the same material base without additional set-up. Combining different variants within a single production run reduces changeover times and costs and helps avoid overproduction. The colour white ensures precise reproduction of fine details on brown corrugated board, including small text as well as QR and barcodes.
The harmonised approach simplifies processes and allows Stiebel Eltron to introduce new solutions faster without the need for additional box tests. Using existing material specifications, new packaging designs can be adapted while avoiding added production complexity. The concept also ensures efficient handling of smaller volumes and consistent branding across regions with high-quality printing supporting the premium positioning of Stiebel Eltron’s products.
Adam Fros, Head of Product Development Building Services at Stiebel Eltron, said: “By supporting us through every phase of the packaging redesign, Mondi delivered a holistic concept that helped us reduce complexity and improve efficiency through an optimised packaging approach. At the same time, white digital printing gives us the flexibility to adapt designs quickly, providing a scalable basis for future product launches.”
The combination of unified corrugated board grades with flexible digital printing technology provides a structured approach for managing complex packaging portfolios. It demonstrates how reducing material complexity, when supported by the right technology, can improve operational efficiency while maintaining adaptability across diverse market requirements.