Mondi helps Stiebel Eltron streamline water heater packaging portfolio

Mondi has worked with Stiebel Eltron to simplify its corrugated packaging portfolio for instantaneous water heaters and small storage units, reducing the number of board grades used by more than 75% while supporting a redesigned visual identity.

Around 150 different corrugated packaging variants were previously used to ship Stiebel Eltron’s water heater products worldwide. The range created complexity across procurement, production and logistics.

As part of the packaging redesign, Stiebel Eltron sought to replace its existing four-colour printed boxes with a new concept featuring white digital printing on brown corrugated board. The objective was to reduce packaging complexity while maintaining product protection and a consistent appearance across the portfolio.

Mondi analysed the existing packaging solutions and grouped formats according to product weight and transport requirements, using reference products representing particularly demanding conditions. It then identified suitable brown corrugated board grades for each product group.

The resulting packaging system reduced the number of different corrugated board grades by more than 75%, while maintaining product protection, according to the companies.

White digital printing was also introduced to support the new packaging design. The technology allows different designs and print volumes to be produced without additional setup and enables multiple variants to be combined in a single production run. It also supports the reproduction of details including small text, QR codes and barcodes on brown corrugated board.

According to Mondi, the streamlined system simplifies procurement, production and logistics, reduces changeover times and costs, and facilitates smaller-volume production. It also provides a common packaging approach across regions and can support faster introduction of new products using existing material specifications.

“By supporting us through every phase of the packaging redesign, Mondi delivered a holistic concept that helped us reduce complexity and improve efficiency through a streamlined packaging approach,” said Adam Fros, head of product development building services at Stiebel Eltron. “At the same time, white digital printing gives us the flexibility to adapt designs quickly, providing a scalable basis for future product launches.”