Antalis has created a bespoke and reusable packaging design for the protection of delicate, custom-made truck lamps.

The reusable packaging comprises laser-cut foam and a corrugated board outer carton, providing protection to truck lighting, while ensuring minimum contact to avoid breakages.

Antalis Packaging’s client manufactures two kinds of custom-made truck lamps which are shipped to an external finisher before being returned and placed into storage.

To avoid damage to the reflector, the lamps can only be touched at designated points, which was challenging for the client when packaging them for transit.

Prior to contacting Antalis, the lamps were packed into polythene bags and placed loose into a box, resulting in damages at a rate of 30-40%.

The Antalis team designed bespoke packaging comprising laser-cut foam and a corrugated board outer carton.

The foam securely and safely holds several lights, making contact only with the safe touchpoints. It was important to create a reusable packaging solution that would provide optimum protection with minimum contact to avoid damaging the lights.

Alan Stanley, account manager at Antalis Packaging, said: “This was a complex design brief. Coming up with a packaging design that would provide sufficient protection while using minimum touchpoints was a real challenge for the design team at the Antalis Smart Packaging Centre, but there is no doubt that they were equal to the task. The client was delighted with the result, especially with the fact that the packaging is reusable, which helps to further improve their environmental footprint.”

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