Chimney Packaging Built for E-commerce Handling & Last-Mile Risk

A Customer-Centric Case Study

A leading kitchen appliance brand required a packaging solution for chimneys sold through e-commerce channels.

These products combine metal bodies with exposed glass surfaces, making them highly vulnerable during last-mile delivery. The existing EPS-based packaging provided basic cushioning but introduced safety concerns and disposal challenges at the customer end.

With increasing online volumes, the requirement was to create a packaging system that could withstand unpredictable handling while remaining practical for large-scale dispatch.

The Situation: Fragile Products in Uncontrolled Delivery Environments

E-commerce distribution exposes products to multiple uncontrolled touchpoints:

• Warehouse sorting and stacking
• Courier handling and transit movement
• Last-mile delivery with variable handling conditions

Chimneys, with glass components integrated into the body, are particularly susceptible to impact damage.

At the same time, EPS packaging presented two key limitations:

Fire and safety risk

EPS is highly flammable, creating risk during storage and transport.

Disposal challenges

End customers faced difficulty in disposing of EPS, leading to poor post-delivery experience and environmental concerns.

The manufacturer required a safer, more practical alternative without compromising protection.

The Engineering Challenge

The packaging system needed to deliver:

• Reliable protection for glass surfaces during last-mile delivery
• Resistance to drops and impact from multiple orientations
• Ease of packing at the factory level
• Efficient transportation in high volumes
• Simplified unpacking for end customers
  
• Elimination of EPS without reducing performance

Honecore’s Approach: Structural Protection with Operational Simplicity

Honecore replaced EPS with a fully engineered honeycomb-based packaging system designed for e-commerce logistics.

The structure was developed to balance protection, usability, and transport efficiency.

Flat-pack architecture

Packaging components were designed for flat-pack transportation, reducing storage space and inbound logistics costs.

Quick-fit assembly

The system allows fast and intuitive fitment, enabling packing teams to maintain speed without complex processes.

Structural cushioning

Honeycomb inserts were engineered to:

• Isolate the chimney body from external impact
• Protect glass surfaces from direct stress
• Maintain positional stability within the carton

The design ensures that impact forces are absorbed by the packaging structure rather than transmitted to the product.

Validated Protection for Last-Mile Risk

E-commerce handling introduces unpredictable drop scenarios.

Honecore validated the packaging through:

• Drop testing from 600 mm height
• Multi-orientation impact scenarios

The system delivered complete protection to the glass components, ensuring product integrity through transit and delivery.

Proven Performance at Scale

The packaging system has been deployed under Just-In-Time (JIT) supply conditions for over four years.

During this period:

• More than 5,000 chimneys have been consistently supplied
• Packaging performance remained stable across repeated dispatch cycles
• Operational efficiency was maintained without disruption

This long-term usage validates both the durability of the design and its suitability for continuous production environments.

Safer and Easier to Dispose

By eliminating EPS, Honecore introduced a fibre-based packaging system that addresses both safety and disposal concerns.

The solution delivers:

• Reduced fire risk during storage and transport
• Easier disposal at the customer end
• Compatibility with standard recycling streams

This improves both operational safety and customer experience after delivery.

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The Outcome