Success story: Sustainable packaging optimisation for BERNINA

Sustainability and efficiency in packaging design have long been key success factors for companies. Our long-standing customer BERNINA, a Swiss company with a long tradition and the world’s leading manufacturer of high-quality sewing and embroidery machines, has also taken up this challenge. For over 125 years, BERNINA has stood for precision, innovation and the highest quality – values that should also be visible in the packaging.

We started a comprehensive optimisation project together, with a focus on partnership-based dialogue from the outset.

The challenge

The wide range of different insert sizes presented BERNINA with a complex logistical challenge: up to now, a separate outer packaging was required for almost every insert.

There was also a desire to replace the existing plastic inserts with more environmentally friendly materials – without compromising product protection.

The solution

Together, we developed a modular packaging solution in which flexible inserts only require a few standardised carton sizes. This has enabled us to significantly reduce the variety of packaging and completely eliminate the use of plastic inserts.

Another important step in the optimisation process: instead of using different types of cartons as in the past, both the inserts and the outer packaging are now made from the same type of carton. This simplifies procurement, increases efficiency in production and ensures a consistent, high-quality appearance.

The result

The new packaging solution has enabled BERNINA to significantly improve its ecological balance, optimise logistical processes and noticeably reduce packaging costs. The reduced material consumption leads to less waste and makes an active contribution to the conservation of natural resources.

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