In order to speed up the packaging processes in its logistics centres, Zalando has re-designed its most common shipping packaging size. The display and packaging manufacturer DS Smith is the development partner and supplier of the optimised solution. Now, the shipping box features an automatic bottom that can be unfolded more quickly instead of the previous folder-type variant. At the same time, the auto-bottom variant helps Zalando to improve its eco-balance.
A sturdier packing scheme not only allows more cartons to be transported per pallet. It also eliminates the need for stretching with film for transport safety. In annual terms, Zalando saves over 200 truck loads and 370,000 m² of film. DS Smith’s tailor-made packaging design is convincing along the entire supply chain and underpins the packaging manufacturer’s high level of expertise in e-commerce.
Uwe Streiber, Lead Packaging Management (centre) and Alex Astanin, Junior Manager Packaging Management (right), both from Zalando SE, are enthusiastic about the re-design of the packaging. Thanks to its automatic bottom, the optimised solution (right in picture) saves valuable seconds in erecting compared to the old folder-type packaging (left in picture). The solution was developed by the display and packaging strategist DS Smith (here represented by the Key Account Manager, Rainer Büttner, left).
In 2018, fashion-loving online shoppers pressed the “buy now” button more than 116 million times in Zalando’s web shop. As a result, over 28 percent more orders were received than in the previous year. Highly efficient processes are required in the warehouse and logistics centres to ensure that goods reach customers punctually and safely despite the growing volume of orders. Every second counts, especially at the packing tables, in order to fulfil the customers’ expectations and wishes for short delivery times in the best possible way. For this reason, Zalando wanted to change its most frequently used packaging size, which corresponds to the volume of two standardised shoe boxes, to an automatic bottom variant, which can be unfolded more quickly. DS Smith’s display and packaging strategists were commissioned with this design change. Their auto-bottom solution follows industrial standards and meets the high load requirements with a stacking crush resistance of 1,400 Newton.
“So far, the feedback from the locations regarding the packaging solution optimised by DS Smith has been consistently positive,” says Alex Astanin, Junior Manager Packaging Management at Zalando SE. “The time saved by the colleagues in the logistics centres during the packing process is significant.” Zalando will therefore roll out the shipping carton successively in all locations, adds the Packaging Manager. Not least because the new auto-bottom packaging from DS Smith not only saves time but also has considerable ecological benefits. Thanks to the sturdier packing scheme, pallets can be used more efficiently when transporting the cartons. The better capacity utilisation is expected to save 200 truck loads per year. At the same time, the company can do without the traditional stretching with film. According to Zalando, the omission of the approximately eight tonnes of film per year alone will reduce its ecological footprint by 20 tonnes of CO2.
“Zalando wants to become the leading platform for sustainable fashion in Europe,” stresses Uwe Streiber, Lead Packaging Management at Zalando SE. “For us, packaging is a strategic topic with great potential for brand building. To achieve our goals, we work closely with partners such as DS Smith, who support us with their packaging expertise in developing sustainable solutions and guarantee consistently high quality in production, even with large quantities and short delivery times.”
