100% Plastic-Free Drop-Tested Packaging for Glass Skincare Bottles

Industry Background

A North American organic skincare DTC brand needed safe, environmentally responsible packaging for fragile glass bottles sold through cross border e commerce. The packaging had to meet EU and North American ESG requirements.

Challenge

Glass bottles were vulnerable to breakage during long distance shipping. The original packaging used EVA foam inserts and plastic trays, which conflicted with the brand’s sustainability goals. The client required zero plastic without compromising product protection.

XingKun Solution

We replaced plastic inserts with molded pulp cushioning and designed a snap fit paper pulp insert that securely held each glass bottle. The packaging structure combined FSC certified paperboard, soy based ink printing, and a corrugated air buffer layer for drop resistance.

Result

The final packaging passed ISTA 1A drop testing from 1.2 meters, reducing reported breakage from 2.5% to 0.05%. The brand achieved 100% plastic free packaging, qualified for recyclability claims, and strengthened its ESG compliance for European market entry.