Transformation Packaging highlighted the benefits of its eco-friendly three-dimensional packaging filler pyramids, ExpandOS, at ProMat in Chicago.
This paper-based packaging serves as a replacement for single-use plastic items like foam bubbles, peanuts, or air pillows while still functioning as a protective cushion for products during transit. It helps manufacturers reduce costs, saves time, and minimizes product damage.
“It’s fully sustainable, 100% recyclable, 100% compostable, 100% biodegradable,” said Sam Gumins, COO of Transformation Packaging, in an interview with Packaging OEM.
How does it work?
ExpandOS paper pyramids are designed to lock together on all three sides, all six corners, and all thirty-eight fingers. When added to a shipping box, the pyramids interlock to stabilize the product and keep it secure in its position inside the box.
“The nice thing is if you press down, it doesn’t move,” said Gumins. “The pyramids are made to interlock, so it doesn’t move in a box, it really offers some great protection.”
Companies can create ExpandOS in their facilities. ExpandOS ships the manufacturer an Expander Machine along with sheets of two-dimensional paper, with one pallet able to make 1,000 cubic feet (cF) of material.
The machine takes up about 3’ x 3’ of floor space and has a height of about 6’. It plugs into a standard 100V outlet and takes about 10 minutes to set up, according to the company. The worktable height and hopper dispensing the product can be adjusted to accommodate any box, no matter the size.
“It is the best of all worlds for customers who are looking for sustainable alternatives to plastic,” said Gumins.
The process can be fully automated, including singulating boxes, measuring required packaging material, and dispensing it autonomously. For large outputs, the company offers a high-speed Rotary Expander.
Industries served and branding options
ExpandOS can hold a variety of products in place during shipment, including glass, concrete, and metal parts.
“We have a wide variety of customers,” said Gumins. “We have customers that do porcelain products from tiles to toilets, customers that do spare parts, everything from automotive parts to aerospace parts, so it does anything that people want to protect,” said Gumins.
Companies can also incorporate their branding onto ExpandOS.
Sustainability impacts on packaging
Companies may switch to a paper-based packaging cushion or filler, such as ExpandOS, to address consumer concerns for eco-friendly packaging.
Retail giants like Amazon have also moved to paper-filler for most orders packaged in North America.
Additionally, companies such as Smurfit Westrock and RanPak have debuted paper pallet wrap as an eco-friendly alternative to polyethylene stretch wrap, cutting supply chain emissions.
Machine builders need to be aware of the changing materials because they may need to retrofit existing machinery or acquire additional machinery designed for sustainable products.
To learn more about paper-based ExpandOS, click here. Catch up on the ProMat show by viewing our photo gallery.
