A Real Case of Sustainable Protective Inner Packaging Using Corrugated Cardboard & Eco-Mushroom Cushioning
Who Was the Client? Why Did They Contact Us?
A European manufacturer of professional waterproof underwater equipment reached out to us because they faced a recurring issue:
• fragile camera components and lenses were often damaged during shipment
• current packaging required too many manual steps
• plastic materials (foam, bubble wrap, tape) contradicted their sustainability policy
• product protection was not always guaranteed
They needed a high-impact packaging solution:
✔ maximally protective
✔ fully plastic-free
✔ compact & easy to assemble
✔ adaptable to different models
✔ compliant with European guidelines on sustainability and end-of-life
“Can fragile electronic devices really travel safely without using single-use plastic?” — this is the exact challenge the client asked us.
What Were the Objectives?
Technical & Operational Goals
- Protect both body and lens (two separated components)
- Replace all plastic or petroleum-based foams
- Reduce assembly time
- Work inside standard American box formats
- Allow scale-up for production
Sustainability Goals
- 100% recyclable, biodegradable or compostable
• No single-use plastic
• European certifications & regulatory compliance
• End-of-life clear and traceable (material passport ready)
The Eco-Packaging Solution BOTTA EcoPackaging Offered
A Two-Part Inner Corrugated Cardboard Structure
We designed a protective internal structure in corrugated cardboard with two separated parts:
- One part protects the machine body
- The second safely locks the lens
These two elements can be assembled together easily, following the audiovisual material provided to the client.
Dimensions will be defined in prototyping phase depending on product variations.
Eco-Mushroom Cushioning: The Key Innovation
Padding was developed using our new patented compostable material, based on mycelium & paper fibres:
✔ 100% compostable
✔ shock-absorption studied ad-hoc
✔ suitable for delicate technology
✔ high-performance mechanical resistance
✔ customizable for each product family
This blend of corrugated cardboard + mycelium cushioning achieved perfect immobilization, eliminating risk of impact damage.
Expected Outcomes
Operational Benefits
- Faster packing time
• Standardized handling
• Reduced packaging layers
• Lower logistics costs
Environmental Impact
- No more single-use plastic
• Fully recyclable or compostable components
• Aligns with EU packaging waste directives
• Supports ESG communication & certifications
Bringing sustainability into packaging is no longer a marketing choice — it’s operational intelligence.
Can This Be Applied to Other Industries?
YES. This system can be adapted for:
• electronics / optics / medical devices
• cosmetics & pharma
• luxury accessories
• spare parts and mechanical components
• e-commerce packaging
The design logic always follows the same equation:
Protection = design + material science + end-of-life.
Do You Want to Explore an Eco-Sustainable Packaging For Your Product?
Our certified Eco-Packaging Consultants & EU Ecolabel Experts can support your internal team from:
• sustainability roadmap definition
• product analysis & LCA
• material sourcing & regulatory compliance
• prototyping and scaling
Let’s analyse your product together.
Write to us or book a free introductory call.
