Dutch online pharmacy Plein.nl reports significant gains in packaging efficiency and process reliability following a year-long optimisation programme carried out with packaging company DS Smith.
The retailer installed two new packing machines and overhauled its box design.
It has removed an estimated 20,900 m³ of unused air from parcels each year and done away with 9,200kg of plastic void fill.
Product damage has also improved, with puncture incidents down 25%.
Plein.nl logistics manager Patrick van den Bosch stated: “The packaging machines have had a hugely positive impact on our internal logistics process. Currently, 98% of all our orders are packaged automatically. Cardboard packaging is crucial in combination with these packaging machines.”
The redesign involved new artwork intended to cut ink consumption, a switch to 100% recycled brown corrugated cardboard, and a revised lid construction.
Plein.nl has also adopted an R-flute board, which has reduced space needed for incoming materials and warehouse storage by 30%.
The changes have contributed to lower CO₂ emissions as well as fewer internal forklift movements and pallet changes.
Plein.nl previously relied on legacy box formats that no longer matched its product range, which often resulted in poor-fit packaging and a high dependence on plastic fillers.
Plein.nl marketing manager Janneke Bongartz also highlighted that the company previously experienced 5,000 cases each year of bottles leaking during packing or transit, stating: “Despite doubling our detergent sales, we've managed to reduce the breakage rate by 25% compared to a year ago. This not only reduces waste but also saves our customer service team a tremendous amount of time.”
The company intends to continue examining options to further improve operational sustainability.
DS Smith sales, marketing and innovation director Hiddo van de Ven added: “We at DS Smith are incredibly proud that we were able to help Plein take their packing process and packaging to an even higher level. These excellent results demonstrate that targeted improvements to sustainability can quickly have a major impact, both in reducing waste and optimising logistics processes, and improving the end-user experience.”
