Making the switch from EPS to paper simple with the award-winning ‘Panel Buffer’

Read how Smurfit Westrock developed the ‘Panel Buffer’—a paper based alternative to EPS that delivers reliable protection in a lightweight, space efficient and easily recyclable format.

To help customers protect delicate items such as mirrors, panels and other flat, impact-sensitive products while reducing their environmental footprint, we developed a modular, paper-based honeycomb fitment to replace traditional expanded polystyrene (EPS) packaging.

The Challenge

Many companies still rely on rigid plastic foam such as EPS to protect fragile goods during transport, despite increasing concerns around plastic use, limited recyclability and storage inefficiencies. Although EPS provides strong impact protection, it carries a higher environmental footprint, occupies substantial warehouse space, and often conflicts with customers’ sustainability goals. As a result, businesses have been seeking a packaging solution that matches the protective performance of EPS without its environmental and logistical drawbacks.

The Approach

We created ‘Panel Buffer’, a modular honeycomb packaging element made from paper-based materials to replace EPS components. The honeycomb structure provides excellent cushioning and impact absorption. Sold pre-glued, the fitment integrates quickly into existing packing operations. Its single-piece design protects both edges and corners, making it suitable for different product shapes.

The Result

The ‘Panel Buffer’ honeycomb fitment enables customers to transition from EPS to a fully paper-based, recyclable packaging solution without compromising product protection. It secures fragile items while reducing storage requirements and handling complexity, and can be easily recycled through standard cardboard recycling streams. The solution supports sustainability goals, improves logistics efficiency, and demonstrates that high-performance protection can be achieved with renewable and recyclable materials.

Winner at the 2026 WorldStar Awards

Products used by this client

Honeycomb Packaging & Honeycomb Sheets

Our honeycomb sheets are ideal for creating durable yet lightweight packaging solutions, effective signage, and versatile displays across various industries.

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