one box - many sizes: Smart folding lines provides flexible and sustainable packaging solution  

True optimization happens across the entire value chain
When working to improve a specific process – whether it relates to cost, logistics, or sustainability – it’s essential to involve others in the value chain. A decision made in isolation can easily shift challenges from one link to another. But when we develop solutions that consider the whole, we create real synergy. Our new packaging concept is a result of this thinking.

 In our furniture production, some product lines allow customers to choose from a wide range of dimensions – for example, lengths from 150 to 250 cm and widths from 90 to 120 cm. That flexibility created complexity when it came to packaging: We needed to keep many different box sizes in stock, which increased cost, reduced efficiency, and generated waste.

The Solution: One Box – Many Sizes

We have introduced a new and flexible packaging solution with folding lines in top/bottom cardboard boxes with fefco code 0300 & 0301 that make it possible to adjust the length of the box as needed – without compromising on quality, economy or sustainability.

 For products where the customer, for example, can choose lengths between 150 and 250 cm and widths from 90 to 120 cm, we have developed a standard full-length box (250 cm). The box is equipped with folding lines every 10 cm, so it can easily be cut to the desired length.

The excess cardboard is not thrown away – it is instead used as protection inside the box, which is both practical and sustainable.

The Benefits – Across the Entire Value Chain

For you as our customer (buyer of pre-packed furniture)

Even though we handle the packaging, you still gain several advantages as our customer:

• One box type = consistency and easy handling
  Regardless of product size, you receive the same type of packaging. This ensures a more uniform logistics flow, easier warehouse handling, and a consistent, professional appearance – especially important if you're shipping to stores or end-customers.
• Smarter use of packaging material
  The cardboard that is cut off is reused inside the box as filler. This means we use the full value of the material, reduce waste, and avoid the need for additional packaging elements.
• Built-in sustainability
  You receive a product that includes a thoughtful and efficient packaging concept without needing to make any extra decisions. It strengthens your sustainability profile effortlessly.

For us as manufacturer

The solution also brings significant improvements to our own operation:

• Optimized inventory and fewer item numbers
  We only need to keep one type of box in stock for a wide range of products. This saves storage space, reduces errors, and improves packaging speed.
• Faster, more flexible packing process
  We don’t need to search for the right box for each product – we simply cut to size and pack. That makes our production more efficient and agile.
• Cost advantages from larger-volume purchasing
  We can order one type of box in bulk, which leads to better pricing and fewer procurement steps – savings we can pass on through more competitive pricing.
• Less waste, more reuse
  Instead of discarding offcuts, we reuse them directly in the packaging. It’s both cost-efficient and resource conscious.

For our packaging supplier

The shift also benefits our upstream partner:

• Larger and more consistent orders
  Instead of many small runs in different sizes, they produce one format in higher volumes, improving efficiency and reducing changeovers.
• Lower transport impact and smarter logistics
  Fewer item numbers and larger batches mean fewer shipments and a lower CO₂ footprint throughout the supply chain.

Optimizing Together – for a Stronger, Smarter Solution

This packaging concept shows how real improvement happens when we look beyond our own operations. By involving our supplier and thinking about your experience as a customer, we’ve created a solution that uses fewer resources, simplifies operations, and adds value at every step – from material sourcing to end delivery.