When a process repeats across thousands of units, even a small material change can create a meaningful sustainability benefit. At the Reconext Bydgoszcz repair center, our team introduced a new terminal packaging design that removes plastic bags and bubble wrapfrom the outbound shipment process.
Previously, each repaired terminal was wrapped in a plastic bag, then wrapped again in bubble wrap, and then packed into a shipping carton. The new approach uses a redesigned carton that holds the terminal securely without those added plastic layers.
By building the protection into the carton itself, the Bydgoszcz team removed two packaging steps from the workflow. The result: less plastic used every time a terminal ships.
Before:
After:
Designing Out Unnecessary Plastic
The improvement started with a packaging design question. Could the carton provide the protection that previously came from added plastic materials?
The Bydgoszcz team focused on function before material choice. Packaging components should earn their place in the pack-out by protecting the product, controlling movement, or supporting handling. When the carton could perform those jobs directly, the extra plastic layers no longer needed to remain in the standard process.
Better design made the material reduction possible without reducing the level of protection.
Reducing plastic at the packaging-design stage is especially relevant in Europe, where plastic remains a major part of the packaging waste stream. In 2023, plastic accounted for 19.8% of all packaging waste generated in the EU, and less than half of plastic packaging waste generated per person was recycled. (ec.europa.eu)
A More Repeatable Packing Process
The packaging change also simplified work at the packing station.
Previously, operators had to prepare multiple packaging materials before closing each shipment. The revised carton removes that extra handling and gives the team a more direct pack-out process. And because the carton guides the terminal into the correct position, operators can achieve a more consistent pack-out with less manual adjustment.
Sustainability Through Better Operations
Sustainability is central to Reconext’s mission, from extending product lifecycles to reducing waste in daily operations. At Bydgoszcz, a small packaging upgrade shows how that mission becomes part of the work. Every improvement counts, and we are proud to make our packaging process a little greener.
