DS Smith and BSH Home Appliances Group have developed a fully recyclable, plastic-free packaging solution for Bosch hand mixers, replacing expanded polystyrene inserts with corrugated cardboard protection in a move that reflects the broader shift toward fibre-based packaging in household appliances. The project was carried out with BSH Hisni aparati d.o.o. Nazarje, the group’s Slovenian unit, and is positioned as a practical example of how manufacturers can reduce plastic use without weakening pack performance or disrupting production.

The new design directly addresses one of the most persistent issues in small appliance packaging: the dependence on EPS protective inserts for shock absorption and product stability. Although EPS has long been used because it is lightweight and effective, it is increasingly challenged by sustainability targets and waste concerns. By moving to corrugated cardboard inserts, DS Smith and BSH are showing that fibre-based structures can now take over applications once dominated by plastic foams, while still meeting transport and handling requirements.

According to the companies, the packaging innovation is expected to eliminate up to 340,000 EPS units every year. That makes the project more than a simple design update. It turns a packaging change into a measurable reduction in problematic material use and aligns with BSH’s wider ambitions to lower CO2 emissions, reduce plastics and advance more circular packaging systems across its operations.

The significance of the project lies in proving that plastic-free protection can work at industrial scale, not just as a sustainability concept but as an operational solution.

The business case is strengthened by the fact that the fibre-based inserts also improve efficiency on the production side. The packaging uses a universal design that fits three different Bosch hand mixer models, reducing complexity in inventory and simplifying line-side handling. The companies also say assembly is faster, which creates additional savings on the packaging line. In other words, the change is not only about replacing one material with another, but about redesigning the pack in a way that improves workflow as well as environmental performance.

That practical dimension is important because many plastic-free packaging initiatives struggle when they require major capital spending or complex production changes. In this case, the new corrugated solution reportedly fits into existing production lines without the need for modifications. It has also passed the required transport and drop tests, confirming that the packaging can protect the product through distribution without compromising safety or quality. For appliance makers, this kind of compatibility is often what determines whether a sustainability-led redesign can move from pilot stage to mainstream rollout.

The production context gives the project additional weight. BSH Nazarje manufactures up to 170,000 units per year, meaning the packaging redesign sits within a real, high-volume industrial environment rather than a limited trial. That scale matters because it shows how quickly packaging changes can translate into substantial reductions in plastic use when applied across established consumer product lines.

For the packaging industry, the collaboration highlights a clear direction of travel. Corrugated and fibre-based protective packaging is moving into roles that were once seen as too demanding for anything other than plastic or foam. As regulatory pressure, retailer expectations and corporate sustainability commitments continue to accelerate this transition, solutions will be judged on whether they can match conventional materials on protection, line efficiency and cost discipline. The Bosch hand mixer pack developed by DS Smith and BSH suggests that, in small appliance packaging at least, that transition is becoming increasingly credible.