Improving Packaging Efficiency and Product Protection with a Custom Reusable ESD Solution

DSM CASE STUDY

Industry: Transportation Electronics

Product Type: ESD-Sensitive Electronic Assemblies (PCBA)

Services Provided:Custom Reusable Packaging Design, ESD Validation, Logistics Optimization, Cost & ROI Analysis Support

Customer Overview

For electronics manufacturers, packaging plays a critical rolex role in protecting sensitive assemblies, supporting efficient production workflows, and minimizing environmental impact. When packaging is not optimized for the product and process, it can lead to increased handling time, higher shipping costs, and unnecessary material waste.

DSM partnered with an established OEM to develop a custom reusable packaging solution designed to improve product protection, increase shipping efficiency, and reduce overall packaging waste across the supply chain.

Challenge

The customer required a packaging solution that would:

• Protect ESD-sensitive electronic assemblies during transport and handling
• Support efficient loading and unloading on the production floor
• Reduce overall packaging footprint and shipping volume
• Align with sustainability goals by minimizing single-use materials

Existing packaging methods were not optimized for the product geometry or logistics requirements, resulting in excess packaging materials, larger box sizes, and increased handling time.

Solution

DSM worked with a specialized third-party packaging supplier to design and qualify a custom reusable ESD blister tray combined with shielding bags, tailored specifically to the customer’s assembly and logistics needs.

Key elements of the solution included:

• Custom tray geometry to securely hold each unit in place, preventing movement and contact during transport
• Reusable ESD-safe materials selected to meet industry protection requirements
• Optimized tray layout to maximize unit count per shipment while maintaining protection
• Shielding bags to provide additional ESD protection throughout the shipping and storage process

All packaging materials were tested and qualified to applicable industry standards to ensure consistent product protection during handling and transportation.

Results

Through collaborative design, testing, and qualification, DSM delivered a packaging solution that improved:

• Product protection and handling reliability
• Manufacturing efficiency on the production floor
• Shipping utilization and logistics performance
• Environmental impact through reduced material usage

This project highlights how packaging, when treated as part of the manufacturing system rather than an afterthought, can deliver meaningful gains in efficiency, cost, and sustainability.

Manufacturing and Logistics Benefits

The new packaging design delivered improvements across both production and logistics operations:

• Reduced handling time through easier loading and unloading at each process step
• Improved protection of sensitive assemblies, reducing the risk of damage
• Smaller overall box size and footprint, allowing more units per shipment
• Better stackability and transport efficiency throughout the supply chain

By integrating packaging design into the overall manufacturing strategy, DSM helped streamline both internal operations and outbound logistics.

Cost and Sustainability Impact

In addition to operational improvements, the reusable packaging solution supported both cost control and sustainability objectives:

• Reduced consumption of single-use packaging materials
• Lower packaging-related waste sent to disposal
• Fewer shipments required due to higher unit density per box
• Opportunity for long-term cost savings through reusable packaging cycles

DSM also supports technical cost and ROI analysis for packaging solutions, helping customers quantify savings opportunities and evaluate long-term impact across production and logistics

Supporting Smarter Manufacturing Systems

At DSM, packaging solutions are developed as part of a broader focus on manufacturability and production optimization. By combining engineering input, supplier collaboration, and industry-standard validation, DSM helps OEM partners improve product flow from assembly through delivery.

Whether supporting early design stages or high-volume production programs, DSM works with customers to identify practical improvements that strengthen manufacturing performance and long-term supply chain reliability.

Reach out today: dsmsales@dynamicsourcemfg.com

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