The Three Cs: Innovations in Computer Packaging Design

The Three Cs of Smart Packaging

Dell has implemented a plan to simplify and revolutionize computer packaging that will result in estimated savings of more than $8 million and the elimination of approximately 20 million pounds (10,000 tons) of packaging material from 2008 through 2012.

Our Dell Packaging engineering team continuously develops and reviews improved packing methods that use the least amount of packaging material possible, while still protecting product shipments. We want to lead the industry in this area — creating a metric where one doesn’t currently exist. We have a deliberate and innovative strategy to increase the sustainability of our packaging. We call it the Three Cs:

• Cube — How big is the box? Could it be smaller? 
• Content — What is the packaging made of? Could it be made of something better? 
• Curb — Is it easily recycled?

In December 2008, we committed to eliminating 20 million pounds of packaging by 2012 by:

• Shrinking packaging volume by 10 percent (cube) 
• Increasing to 40 percent, the amount of recycled content in packaging (content) 
• Increasing to 75 percent, the amount of material in packaging to be curbside recyclable (curb)

We have already made great progress toward our commitment. We’ve reduced packaging volume by 11.7 percent, surpassing the original goal of a 10 percent reduction. So far, we have increased the amount of recycled content in packaging by approximately 33 percent. We have increased the amount of materials in packaging to be curbside recyclable to 68 percent. In fiscal year 2011 alone, we eliminated 6 million pounds of packaging material. 

Picking the Right Material

Packaging consists of the box and the cushioning. We can help our customers by selecting the right packaging material and using less of it:

• Recyclable boxes — Our business client product boxes are made from corrugated cardboard, which is 100 percent recyclable. We use a large amount of recycled cardboard in our new cardboard, but we can’t use 100 percent recycled content because it would lack the necessary structural integrity. So, we focus our efforts on reducing the size of the box (cube). One of the most efficient methods for reducing box size is through the use of our multipacks. When a customer orders several of the same products, upon request, we can bundle them together in a way that greatly reduces the amount of packaging material our customers have to deal with after the equipment is unpacked.
• Recycled cushioning — For many reasons, we’re experimenting with a variety of materials to create our cushioning. Regional cost differences and regional environmental concerns must be considered. For products such as the Dell Inspiron™, we use thermal-form high-density polyethylene (HDPE), which contains 100 percent recycled content* from items such as milk jugs and detergent bottles that are 100 percent recyclable. We have introduced new packaging, such as air cushions in Europe, and other cushioning material, such as thermal-form HDPE cushion, in our effort to accomplish the goals of the Three Cs program.
• Sustainable bamboo — In 2009, we began shipping Dell Inspiron Mini 10 and 10v netbooks in packaging made from bamboo, a highly renewable, certified compostable material that serves as a great alternative to molded paper pulp, foams and corrugated cardboard often used in packaging. As of 2011, we use it for the Streak, the Venue and Venue Pro, and about half of all Inspiron models, with more products to come. We encourage customers to add bamboo packaging to their compost piles for easy, environmentally responsible disposal.

Reducing Waste with Multipack

For orders of multiple systems going to the same location, we offer Multipack — a packaging option that enables multiple systems to be shipped in a single box. Multipack is offered on a limited basis but is available for most servers, OptiPlex™ desktops and Latitude™ laptops. For our PowerEdge™ M-Series blade servers, we have taken Multipack to new heights, and ship a fully configured chassis in a single box. This enables our customers to unpack and start up their new blade servers in about 15 minutes.

Multipack packaging types include:

• Server Multipack — Expanded to M1000E Multipack, which holds eight blade systems, saving an estimated 363 tons of packaging material annually
• Asia OptiPlex MT packaging — Saving an estimated 478 tons of packaging material annually 
• Europe OptiPlex MT packaging — Saving an estimated 216.8 tons of packaging material annually 
• US laptop box packaging — Saving an estimated 317 tons of packaging material annually 
• Inbound piece-part packaging for a variety of components — Saving an estimated 977 tons of packaging material annually

Future Packaging Projects

The packaging life cycle is complex, and it can be difficult to determine which materials offer the best environmental solutions. Our packaging engineers consider methodologies such as life-cycle assessments and carbon-footprint analyses to compare the environmental effects of different packaging. Using these methodologies to quantify packaging material and related logistic models helps us profile and select the best solutions. Some of these future packaging product types are:

• Air-filled cushion technology 
• Molded paper pulp cushions 
• Recycled HDPE thermal-formed cushions 
• Renewable resource packaging materials, such as starch-based foam

 ___________________________________________________________________________________________

*100 percent recycled content for all Dell cushions, except those from India, where there are significant challenges in sourcing recycled polyethylene that passes Restriction of Hazardous Substances (RoHS) Directive testing.