Electronics
·
Austin, TX
·
Hush swapped plastic trays for pulp without changing the box
An audio brand wanted to drop plastic trays but keep their box exactly as it was. We shaped a pulp insert to fit the existing dieline.
Order
12,000 inserts
Result
4.1 t of plastic avoided a year
Speed
16 days to delivery
The box
Printed mailer with molded pulp insert
Keep the box, change the inside
Hush had a mailer they loved and a vacuum-formed plastic tray they didn’t. The ask: remove the plastic without touching the outer box.
The insert
We modelled the earbud case and cable cavities from their CAD, printed a test mould and sent three insert samples in four days. The second one fit.
Drop-tested
Twenty boxes dropped from one metre onto concrete, corners first. No movement, no scuffs.
Impact
Across 12,000 units a year that’s 4.1 tonnes of PET plastic replaced with recycled newsprint.
Rafa Moreno, product lead
