Smurfit Kappa’s compact bumper packaging solution halves truckloads, cuts emissions, and streamlines assembly for automotive suppliers

High bumper demand but outdated packaging solutions

According to the ADAC (German Automobile Club), almost one in four traffic accidents in Germany occurs when turning, entering, or crossing junctions. Adding classic rear-end collisions at traffic lights or in congestion, it is no surprise that bumpers are among the most frequently replaced spare parts in the automotive industry.

Despite strong demand for bumpers – and, consequently, for bumper transport packaging – standard packaging remains far from innovative.

“The packaging in which bumpers are transported is usually very bulky,” says Thomas Axler, Head of Sales for the Automotive division at Smurfit Kappa. The manufacturer of paper-based packaging solutions operates plants specialising in packaging for the Heavy Duty XL sector, where large-format packaging is produced. The challenge is that the larger and more complex the packaging, the more time-consuming its assembly and disassembly for automotive suppliers and affiliated companies, such as vehicle part painters.

Double transport capacity per truckload

Smurfit Kappa’s automotive packaging team recognised the need for change. Traditionally, bumpers were packed using simple bottom-and-lid flaps. Later, so-called U-shaped boxes were introduced, explains Patrick Klocke, key account sales manager, Smurfit Kappa.

Yet, bumper packaging remains a logistical challenge. It cannot be folded compactly, meaning special pallets are required to transport flat-packed goods – or up to six Euro pallets per stack.

The new bumper packaging solution from Smurfit Kappa is significantly more compact and can be delivered on a single Euro pallet. “Depending on bumper contours, we can fit twice as much packaging into a truck and, consequently, into our customers’ warehouses,” says Klocke. This effectively eliminates every second truck journey, leading to major cost and emissions savings. Another advantage is that the packaging can now be stored in high-bay warehouses, improving inventory efficiency.

Automatic base accelerates assembly and reduces labour

From a packaging specialist’s perspective, the greatest advantage of Smurfit Kappa’s solution is its time-saving assembly.

“Until now, bumper packaging has required time-consuming interlocking. Typically, two employees are needed to prevent one side from opening while the other is secured, often taking several minutes per package,” explains Klocke.

The new solution simplifies the process entirely. “Our packaging features an automatic base firmly attached to the ring,” he says. “When set up, it locks into place immediately and can be assembled, loaded, and sealed in a fraction of the usual time – and with just one person.”

A patented innovation in automotive packaging

While automatic bases are commonly used for smaller packaging, they are a novelty in large-format packaging for complex shapes such as bumpers. Smurfit Kappa has patented the development, which took several years to perfect.

The first OEMs and suppliers have already adopted the new concept, and interest in the automotive industry is high. With mounting pressure to save costs, improve efficiency, and decarbonise supply chains, optimising packaging is a small but crucial step.

Smurfit Kappa’s innovative packaging solution offers a practical way to reduce logistics costs and emissions while streamlining warehouse and assembly operations.

This article first appeared on Automotive Logistics’ sister site, Neue Verpackung.