Pack Vac
Modular, reusable thermoformed packaging system
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Project duration : 3 month (2023.04 - 2023. 07)
Role : product designer /Research, ideation, sketching, prototyping, model making, photography.
Project type : Self-produced project
Award: Sächsische Staatspreis, nominated
"Reusable Polystyrene Packaging "
A large portion of polystyrene packaging used for household appliances is not recycled and is simply discarded. To address this issue, we set out to develop a reusable packaging solution. Our response is a new concept in which polystyrene beads are vacuum-formed to create a protective structure that securely cushions the product.
Conventional single-use polystyrene packaging
Protective, Reusable, Visible
We tested EPP, EPS and E-TPU under vacuum to find the most reusable option. EPP was selected for its light weight, resilience and ability to spring back after compression
Hexagonal EPP Cells Under Vacuum
Through vacuum tests we examined how particle size, fill level and sealing patterns affect protection. The final design groups EPP beads into hexagon-like cells that interlock under vacuum, creating a tight, protective wrap that stays flexible and reusable.
Pack Vac
PackVac is a modular packaging system that enables companies and end users to securely and individually package products of various sizes and shapes — without fusing the EPP particles. The modules are composed of recyclable PE film and EPP particles.
S
800 X 322 cm
120g
Orange/Schwarz
PE/EPP
M
800 X 443 cm
170g
Orange
PE/EPP
L
1180 X 443 cm
310g
Orange
PE/EPP
Return system: deposit scheme
By placing the packaging module into a deposit box, it is identified via a QR code and returned to the manufacturer through an international deposit system, where it is then recycled.
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