David Sly

How it works:

The washing machine and ‘SafeShell’ packaging assembly is delivered to either direct customers or retailers by ArrowXL. For direct customers, ‘SafeShells’ are ‘parcelled up’ for return to Ebac. For retailers, ArrowXL recover ‘previous’ ‘SafeShell’s’ for return to Ebac. Retailers replicate this process with their customers. On subsequent Ebac visits ArrowXL return previous ‘SafeShell’ parcels. Hence, no extra journeys are involved in the R2R system.

Problem:

The starting point was a ‘Constructive Discontent’ with the current, ‘single-use’ EPS white goods packaging, including factors like:

• Problematic disposal of EPS/PE packaging.

• Huge negative environmental impact caused by EPS burning or landfill disposal.

• Current EPS white goods packaging materials are not only expensive to recycle but are too fragile to be reused.

Having researched how ‘white goods’ are currently packaged by several leading companies it was decided to narrow the project focus, into improving only the packaging of Ebac’s washing machines, due in great part to their interest in changing product packaging to comply with recent UK and EU legislation. Replicating a ‘virtual’, client/designer scenario, research focused on how Ebac Ltd packages and handles its washing machines and how, possible improvements could be made.

Brief:

To replace Ebac Ltd.’s existing, fragile ‘one-use’, EPS foam and PE shrink wrap, washing machine packaging, with a more robust, reusable and/or recyclable solution, that also affords better product protection.

Key drivers for any packaging solution to fulfil are:

• Comply with relevant legislation

  
  

  (EU, 2023), and (GOV.UK, 2024), relating to disposal of white goods

  
  

  packaging.

• Minimise, the current 150 yearly

  
  

  damaged products, through enhanced protection.

• Be robust enough to withstand

  
  

  being reused many times.

• Materials will be recyclable at

  
  

  the end of their useful life.

• Be cost effective.

‘SafeShell R2R’ addresses these priorities by:

• Replacing ‘single-use’ expensive/difficult to recycle materials with, multi-use’ regulation compliant alternatives.

• A rigid and robust ‘frame’ around the product, affords high protection, and minimises damage.

• Polypropylene is tough and resilient imparting great strength and longevity.

• Polypropylene is fully recyclable at ‘end of life’.

• All but eliminates the need to remake replacements. 

Context:

Packaging Ebac’s 10,000 washing machines a year has huge negative environmental impacts, with EPS being very costly to recycle. White Goods Packaging legislation has recently been introduced by the (EU, 2023), and (GOV.UK, 2024). These two factors necessitated incorporating a more reusable/recyclable packaging material. Annual product damages of 1%–2% equate to 150 items. Thus, using Ebac’s figures their yearly losses are around £60,000. This prompted the design and choice of materials to give enhanced product protection.

Note:

‘SafeShell R2R’ also has the potential to diffuse beyond a solution just for Ebac Ltd, as with only a limited range of dimensions to cover, it could easily be applied to replace the EPS/PE packaging common to all types of white goods/large household appliances.