Molded Pulp Trays for EV Chargers & Power Accessories: High-Value, Low-Waste Shipping
EV charger kits bundle a heavy control unit, coiled cable, and mounting brackets. Loose-fit packaging lets the cable scratch the unit's finish, and the weight demands real crush protection.
The Scenario: A 3.4 kg charger kit that arrived unscratched
An EV accessory brand was shipping a 3.4 kg home charger kit. The control unit arrived with scuffed enclosures in 1 in 15 shipments, caused by the cable coil rubbing against the unit during transit.
Pain Points
- The coiled cable abraded the charger's painted enclosure;
- Loose brackets rattled and dented thin-wall covers;
- Foam blocks added volume and cost to an already heavy parcel.
The Solution: A cradle for the whole kit
The brand moved to a molded pulp tray with a recessed pocket for the charger body and a channel that locks the cable coil in place. Brackets sat in their own formed slots:
1. Cable-locking channel A formed channel holds the coil rigid, so the cable cannot reach the unit.
2. Dedicated bracket slots Each mounting bracket has a pocket, ending rattle and denting.
3. Crush-resistant deck The tray's dense deck and ribbed walls carried the kit's 3.4 kg through stacking.
The Result: Finish intact, volume down
Scuffed-enclosure complaints dropped to zero in the next quarter. The tray's tighter footprint cut parcel volume 22%, and the brand removed the foam blocks from the BOM.