Sustainable packaging solution for e-commerce: mymuesli saves almost 50% packaging material and 30% transport volume in the online segment with the help of Smurfit Kappa

In order to reduce this to a minimum in the future and to improve transport utilisation, the company mymuesli, supplier of customisable organic muesli, worked with packaging specialist Smurfit Kappa to find an improved and sustainable packaging solution. The effects are considerable: among other things, around 50 per cent packaging waste can be saved and 30 per cent more transport volume per truck can be achieved.

In the summer of 2007, three students from Passau launched their business idea: an organic muesli that can be individually put together according to customers' wishes. Since then, the former online start-up mymuesli has developed into a pioneer for individualised organic food and today ships its diverse product range to 9 European countries. The company pursues a clear sustainability strategy in which low-emission and low-packaging shipping options play an important role.

In order to make its shipping area more sustainable, the company analysed and reorganised its entire packaging system in 2020/21. The previous manual dispatch of customer orders with prefabricated cardboard boxes and adhesive tape was not only labour-, material- and time-intensive for mymuesli, it also allowed little flexibility to respond to customer-specific order volumes. They were also looking for new ways to reduce damage to the product packaging during the delivery process.

From manual to automated packaging

In close cooperation with Smurfit Kappa, the specialist for paper-based packaging solutions, mymuesli evaluated all shipping-related processes and work steps - starting with the unfolding of the shipping cartons and the packaging of various breakfast products to the gluing and shipping itself. It became apparent that there was significant potential for optimisation along this entire packaging and shipping process.

Boris Maschmann, CEO of Smurfit Kappa in the DACH region, explains: "The analysis of the processes at mymuesli revealed that, in view of the now high demand for mymuesli products, packaging by hand is no longer efficient and economies of scale do not make themselves fully felt. We therefore suggested investing in a modern packaging machine. With this solution, mymuesli will save costs as well as packaging and additional material in the future."

Customised and precisely packed via 3D scan

The choice fell on the most innovative solution on the market: the CPV-Everest packaging machine from Sparck Technologies, a high-speed packaging machine for continuous corrugated board with a capacity of 1,100 packages per hour for multiple or individual order items. The CVP-Everest is an automated solution that produces precision-fit packaging thanks to its integrated 3D scanner. It is the ideal solution for e-commerce operations facing increasing order volumes and labour shortages. In addition, thanks to a special bottom-lid design, the machine offers a single-material solution with hotmelt that allows the carton to be opened via a perforation in the cardboard. This eliminates the need for adhesive tape to seal the carton.

Philipp Kraiss, co-CEO and co-founder of mymuesli, comments: "Smurfit Kappa's extensive experience in the packaging sector helped us to make the right decision. However, this not only results in a long-term investment in greener value chains, but also offers a quick payback."

Great savings effects, less risk, more flexibility

In spring 2021, mymuesli's innovative packaging unit went into operation for the first time in the German market. The resulting savings are considerable: 20 per cent packaging material for the carton and filling material that is no longer needed is avoided. In addition, the corrugated board waste can be returned to the Smurfit Kappa plant in Feucht for the production of new corrugated board, resulting in a further material saving of around 30 per cent. Thanks to the reduction in volume, optimally adapted package sizes to the contents of the shipment, up to 30 per cent more packages fit into a truck load. At the same time, as a side effect of the customised parcel formats, the risk of the products being damaged during transport is reduced. In addition, 13,500 rolls of tape per year can be dispensed with. Equally important: during seasonal or marketing-specific shipping peaks, such as in the run-up to Christmas or Black Friday, mymuesli can effortlessly increase its capacity thanks to an automated packaging line. The example shows: increased sustainability targets and investments in innovative technologies go hand in hand.