sustainable insert for a heavy duty wooden table

This case study showcases a insert and shipper for a round wooden play table, replacing foam with corrugate. The insert securely locks all table components in place, preventing movement and damage in transit while supporting sustainability, recyclability, and a simpler packing process.

Project Overview

deliverables

• Replace molded foam that provided precise cushioning and part separation.

• Secure multiple components (tabletop, legs, accessories) of varying shapes within one shipper.

• Control cost, packing time, and material usage while improving sustainability.

solution

• Engineered corrugated inserts that folds into compartments for legs, and accessories.

• Created a central support and rim protection around the tabletop to prevent edge crush and surface scuffing.

• Designed the outer box and insert as a tight system, limiting internal movement and improving stacking performance.

• Ensured all elements are fully recyclable, eliminating foam while retaining a premium unboxing experience.

outcome and impact

• Successfully removed foam from the packaging system while maintaining or improving transit protection.

• Reduced material complexity by standardizing on corrugated, supporting recyclability and sustainability goals.

• Simplified packing instructions and reduced risk of parts shifting or being missed during assembly.

• Delivered a cost‑effective, brand‑aligned solution that balances protection, sustainability, and operational efficiency.