From Plastic Foam to Fibre: How a Guitar Brand Future-Proofed Its Packaging Without Compromising Protection
The Challenge
A leading WA based guitar manufacturer were packaging their guitars using a combination of EPS, EPE foam and plastic bubble wrap. These materials had protected their products for years, but changing regulations in Western Australia and growing compliance requirements in overseas markets meant their existing packaging was becoming a liability.
These were fragile, high-value instruments across 41 different models, each with unique shapes and dimensions. Previous attempts to find alternatives had fallen short, with some solutions failing to provide adequate protection during transport.
The business needed a packaging solution that could:
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Protect delicate instruments throughout the supply chain
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Work across 41 different guitar designs
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Meet evolving compliance requirements
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Avoid significant cost increases
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Be practical to implement at scale
Most importantly, they needed confidence that making a change wouldn't create new problems.
The Solution
Working alongside sustainable packaging manufacturer Enviro Hanger, we developed a fully fibre-based packaging system designed specifically around the realities of the product range.
The solution utilised adjustable corrugated and kraft fibre components capable of accommodating multiple guitar profiles within a standard packaging format. This replaced the need for all foam and plastic protective components
Specialised fibre neck supports were incorporated to protect the most vulnerable part of the instrument during transit, eliminating the need for plastic foam components.
The Result:
100% Fibre-Based Packaging Solution
All EPS, EPE foam and plastic bubble wrap components were removed from the packaging system.
Compliance Across Key Markets
The new packaging solution supports compliance requirements in Western Australia and the United Kingdom, helping maintain market access.
Protection Across 41 Product Variants
A single adaptable packaging system was developed to accommodate 41 guitar shapes and sizes without requiring multiple moulded solutions.
Improved End-of-Life Outcomes
The packaging can be recycled through existing paper and cardboard recycling streams, making disposal simpler for customers.
Minimal Cost Increase
The transition resulted in an approximate increase of AUD $0.40 per unit, delivering compliance and sustainability benefits with minimal impact on overall product economics.
At a Glance
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41 guitar models accommodated
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100% fibre-based protective packaging
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$0.40 approximate cost increase per unit
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0 EPS, EPE or plastic bubble wrap components
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2 key markets supported through compliant packaging (AU & UK)
See The Feedback From The Brand:
“We were trying to get our head around the new EPR regulation in the UK and SUP bans in WA, but were very confused. Renata revised our packaging and recommended a solution that worked in both markets and was very cost-effective. It allows us to avoid the plastic tax and to avoid being banned from the WA market.”
Need to Replace Plastic Packaging?
Many businesses assume removing plastic foam means compromising product protection.
This project demonstrates how fibre-based packaging solutions can be engineered to protect fragile, irregularly shaped products while supporting compliance, recyclability and commercial performance.
Whether you're shipping electronics, homewares, specialty products or other fragile goods, replacing problematic packaging materials doesn't have to mean compromising performance. With the right strategy and engineering approach, packaging can become a competitive advantage rather than a compliance risk.
If your business is still relying on EPS, EPE foam or other difficult-to-recycle materials, now is the time to understand your options.
AWEN Packaging Consulting helps brands identify practical, commercially viable packaging solutions that meet both regulatory requirements and business goals.