Self-initiated project at Godrej Appliances R&D
Patent Applied
Environmental Impact of EPS Packaging
Expanded Polystyrene (EPS) is widely used in large appliance packaging for its durability and protective performance. However, its non-biodegradable nature poses significant environmental and waste challenges. This opens up an opportunity to explore alternative materials that balance performance with environmental responsibility.
Expanded Polystyrene (EPS) is widely used in large appliance packaging for its durability and protective performance. However, its non-biodegradable nature poses significant environmental and waste challenges. This opens up an opportunity to explore alternative materials that balance performance with environmental responsibility.
Background Study
Observations from the production line highlighted several inefficiencies in the current EPS packaging system. The use of three large EPS components results in high material consumption and increased storage requirements. The base formation and assembly process is time-consuming and requires additional manpower. Additionally, the bulky EPS parts occupy significant space during storage and transportation, impacting overall operational efficiency.
Ideation
Observations from the production line highlighted several inefficiencies in the current EPS packaging system. The use of three large EPS components results in high material consumption and increased storage requirements. The base formation and assembly process is time-consuming and requires additional manpower. Additionally, the bulky EPS parts occupy significant space during storage and transportation, impacting overall operational efficiency.
Mock-ups and Iterations
Explored various packaging mock-ups to validate design concepts through systematic transit tests - drop test, vibration test, and inclined test.
Transit Tests
Drop test | Inclined test | Vibration test
After several test cycles and refinements, the hybrid solution - integrating corrugated material with EPS proves most effective in protecting the product during drop, vibration, and inclined tests.
Final Solution
Hybrid Packaging
An innovative Hybrid Packaging for FATL washing machines, which integrates the structural integrity of corrugated board with the properties of EPS. This efficient design reduces material costs by 40 Rs per packaging base, while replacing large EPS sections with a corrugated structure that enhances strength and stability during transit. Supplied flat-packed for on-site assembly, this packaging solution optimises logistics and reduces storage space. Additionally, it provides enhanced branding opportunities on the shop floor, allowing for greater visibility and impact.
Existing Packaging
Hybrid Packaging
THANKS FOR WATCHING
This was a self-initiated project, led end-to-end from need finding and concept generation through multiple mock-up iterations, drop testing, and patent documentation. The work was carried out in close collaboration with team members and with support from vendor partners.
