DS Smith has unveiled a sustainable, plastic-free packaging solution for BMW's car wheel carriers, replacing traditional materials with recyclable corrugated cardboard tailored to the parts’ complex 3D geometry.

Created for components manufactured by TPV Automotive, the packaging is engineered to prevent damage during transit by securely housing each eight-kilogram wheel carrier within a robust, compact system.

The fiber-based inserts are delivered flat and assembled on-site using an accordion-fold technique that precisely conforms to the shape of the auto parts, optimizing protection and efficient packing.

Intended for single-use, the packaging is fully recyclable and designed for seamless integration into existing cardboard collection schemes, helping TPV Automotive and BMW reduce their environmental impact and logistics complexity.