New and Sustainable Reusable Transport Box from Fraunhofer LBF

Researchers from the Fraunhofer Institute for Structural Durability and System Reliability LBF, in collaboration with Berges GbR in Darmstadt, have developed and patented an alternative solution to single-use packaging. A fully material-recyclable reusable transport solution for sensitive goods protects the environment and allows users to improve the CO₂ footprint of their companies.

(Darmstadt) Nowadays, cushioning and filling materials used for transport protection consist of plastic flakes and films, air cushions, corrugated cardboard, or wood wool. Recycling of these filling materials is currently not economically viable, which means that modern logistics does not fully exploit significant sustainability potential. The same applies to secondary packaging, as, for example, cardboard boxes are typically used only once. In the case of material recycling, not only the significant energy requirements must be considered, but also the transport routes for disposal and processing. Additionally, there is a scarcity of raw materials that currently particularly affects the transport industry.

Complete System Made of Pure Monomaterial

Here, a novel, fully material-recyclable reusable transport box, developed by Berges in collaboration with the Fraunhofer Institute for Structural Durability and System Reliability LBF (registered utility model DE202017106455), offers an alternative solution to single-use packaging and ongoing resource consumption. In the spirit of a circular plastics economy, the transport box and an integrated functional film are made from the same type of plastic.

Meets Transport Safety Needs

In addition to the aspects of carbon footprint and the necessity of energy savings, this reusable box also meets specific needs for transport safety: Inside the box is a reversibly inflatable air cushion that wraps around the packaged goods when inflated, thus ensuring high transport protection. The air cushion is made from the same material as the outer packaging, resulting in a complete system made of an ideal recyclable pure monomaterial. Furthermore, the air cushion can also be equipped with conductive features for special requirements beyond mere transport security. To significantly reduce transport and storage volume when unfilled, the transport system is foldable after the air is released from the cushion. The transport box and the internal air cushion can be either permanently connected or interchangeable. The transport box is also stackable in the usual manner.

Development Partners for Customized Applications Wanted

Potential applications can occur in both Business to Business and Business to Consumer transports. Possible transport goods include sensitive machine or electronic parts, art objects, high-quality food specialties, or other fragile goods of high individual value.

Application Partners Needed

Application partners are sought for the joint further development of the transport box. Together with Fraunhofer LBF, they can design their individual, customized transport box and thus transport their products and goods safely and sustainably. This saves costs and provides competitive advantages. The recyclable transport boxes can also be individually designed and used for promotional purposes.

Photo: © Fraunhofer LBF, Raapke / Image Caption: The innovative transport box with inflatable air cushion can be individually designed and fully recycled