Case studies

The Carousel toy range has been pre-cycled to remove the twisty ties, metal screws and plastic fittings, all of which make unpacking the product and disposing of the packaging waste frustrating. The new packs are constructed from corrugated cardboard alone and employ die-cut fittings to house, protect and present the product. The average unpacking time per toy across the range was reduced by an average of 4 minutes. 15% Weight Reduction Metal Ties, Plastic and ScrewsFrustration Free & Sustainable Background 0%25%50%75%100% 5% Cube Reduction 100% Sustainable Analysis BeforeAfter 15% Weight Reduction

This project set out to explore the potential to replace the traditional expanded polystyrene (EPS) fittings with corrugated fittings across the radio controlled car category. The new corrugated fitting located and secured the product successfully and passed the ISTA 1A drop test. Waste to landfill was reduced by 29.5 tonnes and cube was reduced by 420m³ - which equates to 12 twenty foot standard containers. EPS, Metal Ties, Plastic and Screws Frustration Free & Sustainable Background 0%25%50%75%100% 8% Cube Reduction 29% Carbon Reduction Analysis BeforeAfter 37% Weight Reduction 20% Cost Reduction

This project required Less to design one approach to light bulb packaging that would accommodate two different merchandising methods for Castorama and B&Q. The challenge being that in the UK light bulbs are merchandised in trays and shopped as if they were fresh eggs, in France they are hung and tested at the end of an aisle. Kingfisher announced a commercial benefit to the London stock exchange in excess of £7m. 15% Weight Reduction Two Retailers : Two Pack Formats Two Retailers : One Pack Format Background 0%25%50%75%100% 8% Cube Reduction 15% Carbon Reduction Analysis BeforeAfter 37% Weight Reduction5% Weight Reduction 20% Cost Reduction

This project was briefed by the client as part of a margin improvement exercise across a major product for the business. The result was a totally new method of transporting bras but also a greener option in terms of recyclability. The new solution also reduced the cost of product damages considerably. 15% Weight Reduction Bras Packed With Tissue Paper Bras Packed With New Pulp Moulds Background 0%25%50%75%100% 25% Cube Reduction 10% Carbon Reduction Analysis BeforeAfter 37% Weight Reduction 20% Cost Reduction

Wine glass 4-packs were optimised to deliver a 50% improvement in production efficiency. This is achieved by slightly changing how the pack is constructed and packed - flipping a pair of glasses to improve nesting and space. There is very little difference in the visual impact, but there is a significant improvement commercially and environmentally. 15% Weight Reduction Current Packaging – 4 Packs Per Printed Sheet New Packaging – 6 Packs Per Printed Sheet Background 0%25%50%75%100% 5% Cube Reduction 50% Production Yield Improvement Analysis BeforeAfter 37% Weight Reduction 40% Cost Reduction 4-up 6-up 12% Weight Reduction

This project set up to achieve two goals. Furniture packaging that protected the planet and the product through all retail channels to market. Less in their solution eradicated all expanded polystyrene (EPS) and significantly reduced damages across the category. The project also involved the mentorship of key suppliers to communicate the new approach and packaging specifications. 15% Weight Reduction 1 Bed – 2 Packs With EPS 1 Bed – 1 Pack Without EPS Background 0%25%50%75%100% 3% Cube Reduction 15% Carbon Reduction Analysis BeforeAfter 37% Weight Reduction 20% Damages Reduction 3% Weight Reduction

This project highlights the connection between environmental and commercial deliverables. This project significantly reduced the carbon impact of the packaging but also by reducing cube delivered cost savings through freight optimization and a reduced pack cost. The reduction in cube combined with the eradication of expanded polystyrene (EPS) also reduced the new French eco-tax by €200 for this product. 15% Weight Reduction 1 Bed – 3 Packs With EPS1 Bed – 1 Pack Without EPS Background 0%25%50%75%100% 11% Cube Reduction 14% Carbon Reduction Analysis BeforeAfter 37% Weight Reduction 17% Cost Reduction

The substitution of EPS with cardboard participates strongly to the total impact diminution assuming the materials are sourced from a sustainably managed forest. - 95% The cardboard recycling process increases the contribution of the end-of-life stages because of the non-production of virgin material which captures CO 2. Approach distribution is the most impacting phase within distribution and the one which is the most impacted by packaging pre-cycling. - 37% Environmental Analysis

CDU Packaging can in certain instances be re-designed using 20-25% less packaging by changing how the pack is constructed. The optimised style can be neatly nested thereby improving the sheet yield, print, die-cutting and sealing productivity. There is very little difference in the visual impact, but there is a significant improvement commercially and environmentally. 15% Weight Reduction Current Packaging – 4 Packs Per Printed Sheet New Packaging – 6 Packs Per Printed Sheet Background 0%25%50%75%100% 41% Blank Size Reduction Analysis BeforeAfter 37% Weight Reduction 19% Cost Reduction 25% Weight Reduction 2 up m 2 up m

The current packaging for these consumer durable items employed a combination of corrugated and thermocol materials. Less re-designed the packaging to reduce packaging and supply chain cost, improve pack performance, eliminate thermocol and enhance the aesthetics of the retail packaging. 15% Weight Reduction Background 0%25 % 50%75%100% 17.5% Blank Size Reduction Analysis BeforeAfter 37% Weight Reduction 13.7% Cost Reduction 28.13% Weight Reduction 11.3% Cube Reduction India National Brand – Consumer Durable

15% Weight Reduction Background 0%25 % 50%75%100% 15% Blank Size Reduction Analysis BeforeAfter 37% Weight Reduction 25% Cost Reduction 25% Weight Reduction 60% Cube Reduction Blister packaging – the pack that consumers dislike with a passion, whether it be physically unpacking the product or disposing of the packaging, it is a frustration to us all. The new pre-cycled pack delivers considerable commercial benefit but also is more visually appealing and easier to shop and display.

Get more from less The Less Packaging Company Asia Limited Units C & D, 11F, Block 1 Camel Paint Building No.62 Hoi Yuen Road Kowloon Hong Kong SAR The Less Packaging Company Limited Thremhall Park Start Hill Bishops Stortford Herts CM22 7WE The Less Packaging Company India PVT Limited Plot 277, Phase IV Udyog Vihar Gurgaon India