Smurfit Westrock Chesterfield has partnered with Dermalux, a producer of advanced LED phototherapy devices, to introduce a fully recyclable and reusable corrugated cardboard box designed to eliminate the use of expanded polystyrene (EPS) while maintaining robust protection during transport.
Crafted from Hexacomb, Smurfit Westrock’s signature paper-based cardboard sheet, the new packaging ensures the safe delivery of Dermalux’s medical devices valued between £3,000 (US$4,030) and £20,000 (US$26,690) without compromising on sustainability or presentation.
“This was a standout project for us, given the high value and delicate nature of the devices,” said Mike Broad, Sales Manager at Smurfit Westrock Chesterfield. “Our team worked hard to create a packaging solution that combines durability, recyclability, and aesthetic appeal. The result is both protective and visually impressive.”
Beyond its protective qualities, the new packaging also elevates the customer experience, providing a premium unboxing moment that reflects Dermalux’s reputation for quality and innovation.
According to Lee Anne Evans, spokesperson for Dermalux, “This solution has genuinely added value to our product. The printed design ties in beautifully with our updated brand identity, while the Hexacomb structure and cardboard components have improved the overall look and feel without sacrificing strength.”
The packaging, currently used for Dermalux’s clinical LED lamp range, features printed branding and messaging for a sleek, high-end appearance. Gerry Maher, Warehouse Manager at Dermalux, added: “The packaging looks fantastic, it’s simple to assemble, and the printed details add a really nice touch. It’s sturdy and professional.”
Smurfit Westrock emphasized that, while EPS offers strong protection, its lack of recyclability and bulky form lead to wasted warehouse space. By transitioning to Hexacomb cardboard, Dermalux has not only made its packaging more sustainable but also cut annual storage costs by approximately £6,000 (US$8,007).
Maher noted: “Our customers now enjoy a cleaner, more seamless unboxing experience no more polystyrene mess to deal with and we benefit from lower storage costs thanks to the more space-efficient packaging.”
Earlier this year, Smurfit Westrock showcased new automation and beverage packaging innovations at Drinktec 2025, including its Bag-in-Box Powergrip, designed to replace traditional HDPE bottles and jerrycans ranging from two to five liters.
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