Navigation and radar equipment for yachts and commercial vessels is, without exaggeration, one of the most valuable product categories currently shipped in corrugated packaging. The price of a single navigation or radar module can easily reach tens of thousands of dollars, while transportation safety requirements are extreme.
For decades, the standard solution in this segment was expanded polystyrene (EPE, EPS). It provided physical protection, but created another issue — packaging that was almost entirely non-recyclable.
However, the wave of sustainability has now reached even this ultra-premium segment.
In the Raymarine project, the transition is particularly illustrative:
the share of non-recyclable packaging components was reduced from approximately 80% to 34%.
This is not a cosmetic change — it is a structural shift.
On one hand, it represents a major step forward in sustainability.
On the other, it involves significant risk, as the packaging must protect equipment of exceptionally high financial and technological value.
That is precisely why this case deserves special attention — and why DS Smith deserves recognition for delivering one of the most interesting and bold projects in today’s corrugated packaging industry.
Extreme Value Meets Extreme Requirements
Raymarine, a global manufacturer of marine electronics, faced two interconnected challenges:
- ensuring the safe transportation of highly sensitive and high-value radar systems across international supply chains
- eliminating single-use plastics without compromising protection performance
“One of our key objectives is to eliminate single-use plastics from our packaging.
Thanks to our collaboration with DS Smith, we are making tangible progress toward that goal,”
— Andrew Smith, Vice President of Supply Chain, Raymarine
Engineered Corrugated Packaging for Premium Equipment
In collaboration with DS Smith, a fully recyclable corrugated packaging system was developed, specifically engineered for Raymarine’s radar product portfolio.
Key characteristics of the solution:
- Protection for ultra-high-value equipment
Radar and navigation systems used on professional and luxury vessels. - 84% recycled content
Compared with approximately 40% in the previous packaging solution. - Complete elimination of plastic
EPE was replaced with engineered corrugated structures.
“This packaging for Raymarine is made from 84% recycled content versus 40% in previous packaging, and it is fully recyclable at end of life,”
— Levente Szabó, Cluster Director, DS Smith Hungary
- Structural and impact engineering
Optimized flute combinations, crumple zones, and fibre-based cushioning to manage shock and vibration. - Logistics efficiency
Flat-packed inserts reduce pallet usage by up to 75%,
while overall CO₂ emissions are reduced by more than 60%.
What This Means for the Corrugated Industry
This case clearly demonstrates that corrugated packaging is no longer limited to FMCG or standard logistics applications.
Today, it:
- enters the highest-value market segments
- replaces plastics in high-risk supply chains
- aligns sustainability and performance instead of positioning them as trade-offs
The key question for the market is no longer:
“Can corrugated packaging protect high-value products?”
But rather:
“What is the next level of value and complexity it can take on?”
About the Companies
DS Smith
A global provider of sustainable corrugated packaging solutions, operating as part of International Paper.
Raymarine
Founded in 1923, Raymarine develops navigation, radar, and communication systems for professional and luxury vessels worldwide.
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