CEM: New eco-friendly packaging for Kärcher pressure washers.
The world's most famous yellow pressure washer is changing its packaging: from polystyrene to cardboard. Discover CEM's ecological transition supported by Ceriana.
The request
CEM SpA is a manufacturing company that is part of the Kärcher Group, a multinational corporation specializing in equipment and solutions for domestic, professional, and industrial cleaning..
Il rapporto di lunga data fra CEM e Ceriana si è intensificato con una co-pA project aimed at redesigning the current protective internal packaging, made of polystyrene, with a new cardboard configuration, quickly and at low cost.
Co-design with Ceriana has resulted in packaging that did not exist before.
CEM turned to Ceriana to increase the overall sustainability of the final product. This strategic operation, to be completed by the end of 2024, will enable the company to continue working with its current customer countries and access the most virtuous markets, which will abolish the use of EPS packaging, including polystyrene, from January 2025.
The transition to an eco-sustainable material, such as cardboard, becomes necessary.
“We also considered cellulose pulp, but unlike cardboard, it requires a significant initial investment, has very long production times, and we were unable to find reliable suppliers.”
Sara Bonezzi - Operation & Purchasing in CEM SpA.
The challenge
CEM asked us to quickly find a solution to replace the protective polystyrene packaging inside the box with a cardboard alternative that was practical, quick to assemble, and, above all, offered the same level of protection..
At the same time, the new solution had to maintain the same packaging costs and assembly times so as not to increase the product's costs.
The circumstances made the search complicated for Ceriana, so much so that there was no substitute product already available.
La soluzione
We found ourselves at a crossroads: should we design pre-assembled or pre-glued interiors.
The option of pre-assembled was discarded because they would have too high a volume with excessive occupation of storage space.
The pre-glued interiors, on the other hand, are quick to assemble in line and transport and storage in the warehouse are facilitated. This option, declared successful, was developed entirely by our technical department starting from a close collaboration with the purchasing and R&D department of CEM.
We studied the production reality of CEM, observing the production lines and the organizational modalities in place. We touched the supply chain by hand, talked to people, and this allowed us to develop inserts that not only adapted to the current packaging, moreover ISTA6A certified, but also to the working methods and production spaces of CEM.
Design, testing and production in record time
In less than 6 months, from the request to the release.
IThe project was initially developed in 3D, then a pilot production was started subject to numerous Drop Tests and Vibration tests. We thus evaluated the performance of the design and materials of the packaging exposed to an external impact force and vibrations during transport. Breaks and critical issues have been identified and resolved, in order to proceed with production.
CEM, What is the most relevant aspect of this project?
“Gain a significant competitive advantage to collaborate with the countries most attentive to sustainability, such as Great Britain, Australia and New Zealand, which from January 1, 2025 apply, first, the EPS ban. In addition, we have marked a first: we are the first production plant of the Kärcher group to have a packaging that meets these eco-sustainability requirements in advance, thanks to the close collaboration with Ceriana we were already ready in September 2024.”
Michele Andreasi, buyer CEM e Alex Bonichini, R&D.
How do you describe the relationship with Ceriana?
“It was the first time I saw such an active and important collaboration from a supplier, who collaborated in supporting us with purposefulness, presence and passion.”
Valentina Araldi, Operation & Purchasing in CEM SpA.
“A very profitable relationship, I think for both of us. We were impressed by Ceriana's responsiveness and their purposefulness, rather rare characteristics to be found in a supplier. Specifically, Marco Barichello took the project to heart as if it were his own, it was integrated into our reality and seemed to be part of our R&D department. The project was overhauled thanks to Ceriana's technical skills, making improvements to achieve the best possible result quickly. We still continue to collaborate in this perspective of continuous improvement.
Sara Bonezzi, Operation & Purchasing in CEM SpA .
