Case Study
Protecting Fragile Products Without Plastic Foam
How Pacard developed a fibre-based packaging solution for guitar packaging
Project: Fibre-based protective guitar packaging
Challenge: 41 guitar shapes and sizes, fragile neck support, and the need to move away from EPS, EPE foam and plastic bubble wrap
Solution: Adjustable corrugated and kraft fibre packaging system with dedicated neck protection
Outcome: A practical, recyclable packaging solution with minimal cost increase.
Overview
When a guitar brand needed to rethink its packaging, the challenge was not simple.
Guitars are fragile, high-value instruments that require strong protection during transport. They also come in many different shapes and sizes, making it difficult to design one standard packaging solution that works across an entire product range.
For this brand, the added challenge was scale and complexity. Their range included 41 different guitar shapes and sizes, and their existing packaging relied on expanded polystyrene sheets, expanded polyethylene foam and plastic bubble wrap.
With packaging regulations changing and growing pressure to reduce problematic plastics, the brand needed a more sustainable solution that would still protect the product, support compliance requirements and remain commercially viable.
Pacard was brought into the project to develop a fibre-based packaging solution that could meet the practical realities of the product and supply chain.
The brief was clear: find a sustainable packaging solution that protected the product, met compliance requirements in Western Australia Single-Use Plastic ban and the UK, and didn't cost the earth, literally or financially.
The Challenge
Most packaging systems are designed around consistency.
Moulded pulp, thermoformed trays and die-cut inserts can work well when every product has the same predictable shape. Guitars are different. Even within the same product category, body shapes, curves, widths and neck profiles can vary significantly.
The brand had already explored airbag packaging, but it did not provide adequate protection during transit. Moulded packaging was also ruled out early because the product variation across 41 SKUs meant a single moulded solution would not work.
The most vulnerable point was the guitar neck.
Without proper support in this area, the risk of damage during freight was too high. Any replacement packaging had to protect this key risk point while still allowing enough flexibility to suit different guitar shapes.
The solution could not rely on rigid, pre-formed geometry. It needed to be adaptable, protective, recyclable and practical for commercial rollout.
Pacard’s Solution
Pacard developed a fully fibre-based protective packaging system designed specifically for this product category.
Rather than trying to force the guitars into a rigid moulded insert, Pacard created a solution using corrugated and kraft fibre components that could be adjusted to accommodate different guitar shapes within the same overall box format.
This adaptability was critical.
The packaging needed to work across 41 different SKUs without requiring separate tooling or moulds for every guitar shape. The final system allowed the product to be supported securely while giving the packaging enough flexibility to suit variations across the range.
A dedicated fibre-based neck support was also incorporated into the design. This was a non-negotiable part of the solution, as the neck is one of the most fragile areas of the instrument.
The support needed to be strong enough to protect the product during transit without reverting to EPS, EPE foam or plastic bubble wrap.
The finished packaging system was designed to be:
Fully fibre-based
Free from EPS, EPE and plastic bubble components
Adjustable across multiple guitar shapes and sizes
Designed with dedicated neck protection
Recyclable through standard paper and cardboard recycling streams
Practical for commercial implementation across the brand’s range
The end-of-life outcome was also an important part of the design.
Sustainable packaging only works when customers understand how to dispose of it correctly. By using fibre-based materials that can go into paper and cardboard recycling streams, the solution created a clearer and more practical pathway for responsible disposal.
The Outcome
The new fibre-based solution allowed the brand to move away from plastic-based protective materials while still maintaining the product protection required for a fragile, high-value instrument.
The increase from the previous plastic-based packaging to the new fibre-based solution was minimal bearing in mind the high cost of the item.
For a product such as a guitar, where the retail value can range from hundreds to thousands of dollars, this increase was minimal. More importantly, it helped reduce packaging risk, improve sustainability outcomes and support the brand’s ability to respond to changing market expectations.
The real commercial issue was not the additional cost.
The greater risk was continuing to rely on packaging materials that may restrict market access, create compliance concerns or weaken the brand’s sustainability position.
This project demonstrated that sustainable packaging does not always require a major financial trade-off. With the right design approach, the cost impact can be modest while the commercial, environmental and compliance benefits are significant.
Why It Matters
This case study demonstrates what is possible when a fragile, irregular or high-value product needs to transition away from traditional plastic foam packaging.
Many industries face similar challenges, including musical instruments, homewares, artisan products, gifting, speciality electronics and premium retail goods. These products often require strong protection but do not suit standard moulded packaging formats.
There is a common assumption that removing plastic means compromising on protection. This project shows that does not have to be the case.
By designing around the product’s real risk points, rather than simply replacing one material with another, Pacard was able to create a packaging system that was protective, adaptable and more sustainable.
For this guitar brand, the critical risk point was the neck. Once that was properly supported, the rest of the packaging could be developed to flex around the product shape while maintaining structural integrity. Pacard also developed a woodfibre bag to protect the premium guitars.
A Collaborative Approach
Projects like this require the right mix of expertise.
Renata Daudt from AWEN Packaging Consulting provided compliance guidance, packaging expertise and the technical brief. Pacard brought the sustainable packaging knowledge, fibre-based product development capability and manufacturing solution.
The client also played an important role by making clear decisions once the solution was developed.
This combination of compliance insight, sustainable packaging innovation and decisive client action allowed the project to move from problem to solution without unnecessary delay.
It is a strong example of how Pacard works with brands, consultants and product teams to solve complex packaging challenges in a practical and commercially realistic way.
If your business is still using EPS, EPE foam, plastic bubble wrap or other difficult-to-recycle protective packaging, now is the time to review your options.
Pacard helps brands transition away from traditional plastic packaging and into practical fibre-based alternatives designed for real-world retail, freight and supply chain conditions.
Need a smarter protective packaging solution?
Talk to Pacard about fibre-based packaging designed for your product, your supply chain and your sustainability goals.