Case Study

Transitioning a national hardware company from plastic to paper for improved sustainability





The problem

A hardware company needed to transition from plastic packaging to a paper-based solution for items sold at Home Depot and Lowe’s.

BoldtSmith was tasked with optimizing master carton sizes, designs, and pallet patterns for 14 SKUs while meeting key requirements such as 100% paper-based packaging, reducing packaging costs, and increasing product density on pallets.

Our approach

We utilized advanced design techniques to create 3D renderings of packaging concepts, allowing for visual evaluation and refinement.

Our approach focused on optimizing master carton sizes, redesigning packaging layouts, and maximizing pallet space utilization while ensuring compliance with sustainability goals and cost reduction targets.


The partnership resulted in significant improvements across multiple metrics.

By transitioning to a paper-based packaging solution, the client achieved a reduction in master carton material, leading to cost savings and environmental benefits.

The optimized packaging design enabled an increase in product density on pallets, maximizing efficiency in shipping and storage.

The removal of plastic annually underscored the company’s commitment to sustainability and environmental stewardship.

Through innovative packaging engineering and collaboration, we successfully implemented a sustainable packaging solution that delivered tangible benefits in cost savings, efficiency, and environmental impact.



Less master carton material


Pounds of plastic removed annually


More product per pallet