Smurfit Westrock‘s Peterborough site has developed a fully paper-based packaging solution for Andersen‘s A3 and A4 electric vehicle chargers, designed to protect the products during distribution while supporting the manufacturer’s sustainability objectives.
Andersen approached Smurfit Westrock to develop packaging for its new charger range within an eight-week timeframe. The brief called for a robust solution capable of protecting high-value products during courier and palletised distribution while providing a premium unboxing experience. The packaging also needed to accommodate multiple components and installation templates, support future ISTA testing requirements and be manufactured from recyclable materials with a natural brown finish.
With physical product samples unavailable during the design phase, the Smurfit Westrock team used CAD software to develop and refine the packaging from technical specifications. This enabled virtual testing of the designs before production, helping ensure the final solution met performance, usability and sustainability requirements.
To support Andersen’s Extended Producer Responsibility (EPR) objectives, the packaging was designed using fully paper-based, recyclable materials. Smurfit Westrock used its paper-to-box application to identify the minimum board caliper required to achieve the necessary strength and rigidity while reducing material use.
The outer case is manufactured from B-flute corrugated board, providing strength alongside a smooth printing surface. A redesigned lid construction features internal flaps that fold 180 degrees inward, helping to improve rigidity and reduce bending during opening and closing. A safe-edge rule was also incorporated into the front opening of the pack to minimise the risk of cuts during handling.
Inside the pack, custom-designed double-wall BC-flute fittings provide cushioning and puncture resistance. The internal layout positions the welcome pack centrally, with integrated finger holes allowing customers to remove it easily before accessing the charger and installation template beneath. Additional fittings secure the charger and smaller components during transport.
Smurfit Westrock applied the same internal fitting design across both the A3 and A4 charger models to provide consistency throughout the product range. Additional side fittings support the chargers from below while protecting the sides during handling and distribution.
According to the companies, the new charger range launched on schedule and exceeded initial sales expectations. The move to a fully paper-based packaging solution also reduced Andersen’s EPR liability compared with foam or plastic alternatives while supporting the company’s sustainability strategy.
“We’re so pleased with how the packaging has turned out, and how well it reflects the quality of our chargers,” said Stephen York, Senior Production Supervisor at Andersen. “It’s fully recyclable, protective and delivers an unboxing experience that our customers love. Smurfit Westrock Peterborough turned our vision into a quality, sustainable solution that exceeded our expectations.”
“Working with Andersen was an exciting challenge.” said Brian Smith, Technical Sales Manager at Smurfit Westrock. “They had a clear vision for what they wanted, and we were able to translate that into paper-based packaging that met tight deadlines, all without compromising on quality.”
