Optimised design reduces packaging complexity by over 75% while enhancing efficiency and print flexibility
As part of a packaging redesign, Stiebel Eltron, a global leader in building services and innovative solutions, aimed to refine a highly complex packaging portfolio for its water heater product range while introducing a new design. Mondi worked closely with the team to develop an optimised packaging concept that supports smooth operations and scalable packaging across regions and new product development.
Managing a wide range of packaging variants across a diverse product range
Around 150 different corrugated packaging variants were in use to ship Stiebel Eltron’s instantaneous water heaters and small storage units worldwide. This variety increased complexity across procurement, production and logistics, making it harder to manage the portfolio and maintain consistency.
At the same time, the company was updating its packaging design. The existing four-colour printed boxes were to be replaced with a new visual concept using white digital printing on brown corrugated board to create a consistent look across the product range. This required a solution that could simplify the packaging portfolio while maintaining optimal product protection and enabling a consistent appearance.
A structured approach to efficiency and optimal packaging performance
Mondi began with a detailed analysis of the existing corrugated packaging solutions. Each format was assessed and grouped according to product weight and transport requirements, using defined reference products with particularly demanding conditions.
Based on this evaluation, Mondi identified the most suitable brown corrugated board grade- for each product group.
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The result was a more structured and unified packaging system that could be applied across multiple products.
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The enhanced packaging portfolio reduced the number of different corrugated board grades by more than 75% while maintaining optimal product protection
To support the new design, white digital printing was introduced. This enables different packaging designs and print volumes to be produced without additional set-up and allows multiple variants to be combined within a single production run.
The printing technology also ensures precise reproduction of fine details such as small text, QR codes and barcodes on brown corrugated board, supporting the requirements of the updated packaging design.
A streamlined packaging portfolio with flexibility for different market needs
The new packaging concept simplifies processes while maintaining optimal product protection:
- Easier handling across procurement, production and logistics
- High-quality printing that supports the premium product positioning
- Reduced changeover times and costs by combining multiple variants in one print run
- Efficient handling of smaller volumes and consistent branding across regions
- Faster introduction of new products using existing material specifications
With the unified packaging system in place, Stiebel Eltron benefits from a long-term approach to packaging that combines consistency and adaptability. This enables Stiebel Eltron to respond to changing product requirements while maintaining a cohesive packaging concept across its portfolioBy supporting us through every phase of the packaging redesign, Mondi delivered a holistic concept that helped us reduce complexity and improve efficiency through a streamlined packaging approach. At the same time, white digital printing gives us the flexibility to adapt designs quickly, providing a scalable basis for future product launches.”
- – Adam Fros, Head of Product Development Building Services at Stiebel Eltron
