DS Smith converts shipping packaging for Zalando

The online mail order company Zalando has redesigned its most frequently used shipping packaging size to speed up the packaging processes in its logistics centres. The development partner and supplier is the display and packaging manufacturer DS Smith.

The shipping carton now has a crash-lock base that can be set up more quickly than the previous tab locking variant. The greater stability of the design means that more cartons can be shipped on each pallet and also eliminates the need for stretch film to secure the load. The online giant saves more than 200 truck loads and 370,000 square meters of film per year thanks to the improved load factor.

This is why Zalando wanted to convert its most frequently used packaging size, which is the size of two shoe boxes, to the crash-lock base, which can be set up more quickly. DS Smith’s display and packaging strategists were commissioned with the design change. The crash-lock base solution meets the high load requirements, explains DS Smith.

“Feedback on the DS Smith optimised packaging solution so far from Zalando sites has been consistently positive,” says Alex Astanin, Junior Manager Packaging Management at Zalando SE. “The time saved in the logistics centres during the packing process is significant.” Zalando will accordingly roll out the shipping carton successively in all its locations. Besides saving time, the new crash-lock base packaging from DS Smith has ecological advantages: according to Zalando, eliminating around eight tons of film a year alone will reduce its ecological footprint by 20 tons of carbon dioxide.


FachPack shows you solutions for shipping – throughout the entire packaging process chain and everything associated with it, from materials to function and design to logistics and tracking. More information can be found here.

“Zalando wants to become the leading platform for sustainable fashion in Europe,” explains Uwe Streiber, Lead Packaging Management at Zalando SE. “Packaging is a strategic topic for us, with great potential for brand building. To achieve our goals, we work closely with partners such as DS Smith whose packaging expertise helps us to develop sustainable solutions and guarantees consistently high quality in production, even with high throughput and short delivery times.”

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