The Challenge
A DTC electronics brand saw 12% damage rate on shipped accessories. Returns and support costs exceeded packaging savings from cheap foam inserts.
The Solution
Custom molded pulp inserts engineered to device geometry. Drop-test validated before mass production. Outer corrugated matched insert footprint to eliminate void fill.
The Results
92%
Fewer shipping damage claims — from 12% to under 1%
100%
Plastic removed from packaging stream — 12 tons annually
4 weeks
Tooling to production for custom insert
“From 12% damage rate to under 1%. Returns dropped 92% in the first quarter. Reduced returns paid for the packaging upgrade.”