Success story: Sustainable packaging optimisation for BERNINA

Sustainability and efficiency have long been central to packaging design. For our long-standing customer BERNINA, the Swiss global leader in high-end sewing and embroidery machines, this presented both a challenge and an opportunity. For over 125 years, BERNINA has stood for precision, innovation, and the highest quality – values that should also shine through in its packaging.

Together, we launched a comprehensive optimization project. From the very start, partnership and dialogue were at the heart of the collaboration.

The challenge

BERNINA faced a complex logistical issue: its wide range of insert sizes required almost every product to have a separate outer packaging. Moreover, there was a desire to replace the existing plastic inserts with environmentally friendly alternatives – without compromising protection.

The solution

Therefore, we developed a modular packaging system. Now, flexible inserts fit into just a few standardized carton sizes. As a result, we could significantly reduce the variety of packaging and completely eliminate plastic inserts.

Additionally, instead of using different types of cartons as before, both the inserts and outer packaging now use the same carton material. This change simplifies procurement, improves production efficiency, and ensures a consistent, high-quality appearance.

The result

The sustainable packaging for BERNINA now reflects the brand’s precision, innovation, and superior quality. Modular solutions, flexible inserts, and unified materials ensure a consistent presentation, simplify production, and reduce waste.

Thanks to the new packaging solution, BERNINA has been able to significantly improve its ecological footprint, optimize logistical processes, and noticeably reduce packaging costs. The reduced material consumption generates less waste and actively contributes to the conservation of natural resources.

This project demonstrates that sustainability and efficiency are not mutually exclusive – they are the key to the packaging of the future.