Case Study | Sustainable Packaging Solutions for Consumer Goods Manufacturer

Functional Topic

Sustainable Packaging Solutions

Project Industry

Consumer Goods Manufacturing

Needed Support

Sustainability Consultant

Duration

8 Months

The Challenge

A global consumer goods manufacturer faced growing regulatory and consumer pressure to adopt sustainable packaging solutions. Stricter regulations like the EU Single-Use Plastics Directive and increasing scrutiny of packaging waste pushed the company to address its reliance on virgin plastics, which contributed significantly to Scope 3 emissions.

The company’s packaging processes were fragmented, with limited visibility into the environmental impact of materials used across global markets. Additionally, over-reliance on virgin plastics contributed significantly to Scope 3 emissions. To address these challenges, the company needed a consultant to optimize its packaging processes using digital technologies.

Role of Consultport

The client engaged Consultport, which provided within 40 hours three qualified consultants experienced in sustainable supply chains and digital transformation. Ultimately, the client engaged a consultant with over 10 years of experience in sustainable packaging projects.

Moreover, the consultant had previously managed over five projects in implementing digital technologies to increase supply chain visibility and optimize packaging design. Tasks included the deployment of sustainable packaging solutions by leveraging cloud-based technologies and digital tools, to move towards a more data-oriented tracking.

The Approach

The consultant followed a three-step approach for the deployment of sustainable packaging solutions and the improvement of the client’s digital capabilities:

Digital Lifecycle Analysis for Material Selection
The consultant implemented a digital lifecycle assessment (LCA) tool to evaluate the environmental impact of various packaging materials. This analysis helped identify opportunities to replace virgin plastics with recycled or biodegradable alternatives without compromising product integrity.

Optimizing Sustainable Packaging Design
Using AI-powered design tools, the consultant worked with the company’s packaging team to redesign the products for material efficiency. Simulations conducted with digital tools enabled rapid testing of multiple packaging configurations, reducing material use and waste.

Real-Time Collaboration with Suppliers
A digital platform was introduced to facilitate communication with packaging suppliers, ensuring that sustainable materials were sourced and tracked effectively. This platform also enabled collaborative innovation, helping suppliers meet the company’s sustainability criteria.

The Results

After the implementation of the sustainable packaging solutions by the consultant, the client noticed consistent improvements in material usage and regulatory compliance:

Reduced Material Usage

Sustainable Packaging redesigns reduced overall material consumption by 8%, significantly lowering the environmental footprint of high-volume products.

Transition to Sustainable Materials

Aligned with the EU directive, the company successfully replaced 40% of virgin plastics in its primary packaging with recycled or biodegradable materials.

Cost Efficiency

Material savings and optimized designs resulted in a 5% reduction in packaging costs across the product portfolio, making the transition financially sustainable.

Enhanced Supply Chain Transparency

Real-time collaboration with suppliers increased the traceability of materials, ensuring compliance with emerging regulations and bolstering trust in the company’s sustainability claims.