SMURFIT Westrock has helped Dermalux, a specialist in designing and manufacturing medical LED phototherapy devices, to protect delicate and high-value products during transit.
Previously, Dermalux relied on expanded polystyrene (EPS) and plastic in its healthcare packaging. While this delivered protection, it made recycling difficult and fell short of a premium unboxing experience.
Dermalux turned to Smurfit Westrock Chesterfield to create medical packaging for clinic-only devices. The brief was to find a solution that securely packaged all parts of the device during transport and allowed for easy assembly, factoring in the heavy main body of the device. Dermalux also wanted to enhance the customer unboxing experience and align with sustainability goals.
The team at Smurfit Westrock Chesterfield designed a custom packaging solution that removed the use of EPS by replacing it with corrugated cardboard and Hexacomb. With the high-value nature of the product – Dermalux’s devices range from £3,000 to £20,000 – finding a recyclable solution without compromising product protection was key.
The new packaging design is also said to improve efficiency as it can be flattened for easier storage, freeing up warehouse space.
By replacing polystyrene buffers with corrugated Hexacomb, Dermalux has eliminated the ‘mess’ of EPS and delivered a ‘cleaner, more sophisticated’ first impression that reflects the quality of the products. The addition of printed branding and messaging is intended to give the packaging a more premium feel, while the ‘thoughtful’ design ensures all device components are held securely and professionally displayed.
The new medical equipment packaging is also reusable, allowing clinics to repackage devices when relocating.
Gerry Maher, warehouse manager at Dermalux, said, “The packaging looks great, easy to put together and it seems to be really sturdy! Really nice touches with the images printed onto the cardboard. Our customers will have an even better experience, without even counting not having to brush up the polystyrene off the floor after unpacking their device. One of our other main drivers was storage costs; polystyrene is very space inefficient and moving to this solution saved us around £6,000 per year in warehouse costs.”
Mike Broad, sales manager at Smurfit Westrock Chesterfield, added, “This was a special project for us, considering the value of the medical devices being shipped, and the team went above and beyond to find a medical packaging solution that ticked every box. The result is packaging that’s protective and recyclable whilst also appealing to customers.”
