DS Smith Tecnicarton and ZICLA develop fibre-based packaging for smart bike-lane separators
Corrugated cardboard solution protects electronic components while optimizing logistics and sustainability.
www.dssmith.com
DS Smith Tecnicarton and ZICLA have collaborated to develop an innovative, fully fibre-based packaging solution designed to protect smart bike-lane separators equipped with electronic counting components. The bespoke solution combines robust product protection with improved space utilization and supply-chain efficiency, while aligning with circular-economy principles.
Sustainable design tailored to product geometry
The new packaging solution is made entirely from corrugated cardboard and consists of two elements:
- An outer box with an integrated tab-locking system that eliminates the need for adhesives or staples, enabling fast and secure manual assembly;
- An internal positioning insert engineered to match the oval geometry of ZICLA’s separators.
The internal insert replaces traditional screws by locking directly into the corners of the corrugated structure, stabilizing the product and protecting sensitive electronic components from friction, vibration, and impact during transport.
One format for multiple product variants
A key feature of the solution is its standardized single-format design, which accommodates two different separator models with distinct geometries and dimensions. This reduces the number of packaging references required, simplifies palletization, and minimizes storage and transportation space. As a result, ZICLA benefits from lower logistics costs, streamlined handling, and consistent protection across its product range.
Engineering-led development process
To achieve the required precision and performance, DS Smith Tecnicarton applied advanced 3D engineering tools to model and visualize the final concept. The development process included a detailed evaluation of handling, assembly, packing, picking, storage, and transport requirements to ensure the packaging met both operational and sustainability objectives across the full supply chain.
Antonio Cebrián, Sales Director at DS Smith Tecnicarton, said:
“Working closely with ZICLA allowed us to transform a complex technical and logistical challenge into an efficient, sustainable, and scalable packaging solution. This project highlights our role as a strategic partner in developing advanced, future-oriented packaging that protects high-value products while optimizing supply chains.”
Supporting circular urban mobility
For ZICLA, the packaging solution reinforces its commitment to sustainability and the circular economy.
“Our new packaging solution is a key step in protecting our smart separators during transport while reducing environmental impact,” said Lain Guio, Chief Operating Officer at ZICLA. “It aligns fully with our values as a specialist in urban mobility solutions made from recycled materials, and the collaboration with DS Smith Tecnicarton was essential to achieving this result.”
Industry recognition
The jointly developed packaging solution received a Liderpack Awards 2025 award in the category Best Packaging in Electronics, Imaging and Sound, recognizing its innovation, sustainability, and technical excellence.
Through its purpose of Redefining Packaging for a Changing World, DS Smith continues to support customers worldwide with fibre-based solutions that advance circular-economy goals while delivering practical performance benefits.
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