Wood-Free Packaging That Delivers Real Business Impact
March 29, 2026
A leading engine manufacturer partnered with Signode to eliminate wood from its export packaging, transitioning from traditional wooden and plywood boxes to an engineered solution. The goal was to improve sustainability while maintaining high standards of protection, efficiency, and cost control.
The transformation began with a complete redesign of the packaging architecture. Signode developed an optimized rack-based solution, validated through rigorous compression, vibration, and rough-handling tests to bring a reliable solution across global transit conditions. The redesigned packs allowed more engines to be accommodated within a smaller footprint, improving space utilization.
As a result, each 20-foot container could now carry 64 engines instead of 48. This translated into a 133% improvement in logistics efficiency, significantly enhancing shipping economics. At the same time, the optimized design delivered 7% direct savings in packaging costs, proving that sustainability and cost efficiency can go hand in hand.
Operational benefits were equally compelling. The elimination of wood removed the need for nailing, reducing sharp edges and improving shopfloor safety. Packing and unpacking became faster and simpler, boosting productivity at both the shipping and receiving ends. Most importantly, transit damages, which earlier averaged four to five engines per shipment, were eliminated.
Beyond operational gains, the solution delivered a strong sustainability outcome. By moving to a reusable system, the engine manufacturer achieved zero wood consumption in packaging, directly supporting its environmental goals and ESG commitments.
This project demonstrates how optimal packaging design can balance protection, cost, and sustainability. Through engineering-led innovation and close collaboration, We helped the customer move to a future-ready, wood-free packaging solution that protects the product, the planet, and the business alike.