The challenge
The Eco VIBE 3+ packaging contains several components, including the toothbrush, charging unit, brush head and accessories. In conventional setups, this type of product typically relies on plastic trays or foam inserts to keep everything in place. HappyBrush wanted to move away from those materials without increasing packaging volume or complicating the unboxing experience.
In addition, the packaging needed to fit within an existing cardboard outer box and remain suitable for large-scale distribution across Europe. Sustainability had to be practical and clearly visible, without introducing new disposal questions for consumers.
The PaperFoam® solution
PaperFoam® developed a custom-molded insert that fits precisely inside the cardboard box. Each component has its own position, preventing movement during transport and reducing the risk of damage. The insert replaces plastic and foam alternatives with a single biobased solution that integrates smoothly into existing packaging processes.
The PaperFoam® material is lightweight and shock absorbing, while remaining recyclable with paper and suitable for composting. This provides a clear and understandable end-of-life route for consumers. More information on material behavior is available on our recyclability and compostability page.
Design and unboxing experience
The molded insert follows the exact geometry of the product and accessories, keeping the packaging compact and organised. This reduces the need for additional fillers and supports efficient stacking during storage and transport.
Combined with the printed cardboard packaging, the PaperFoam® insert contributes to a calm and consistent unboxing experience. The natural texture of the material reinforces the sustainability message without drawing attention away from the product itself.
Impact and results
By switching to PaperFoam®, HappyBrush reduced the use of fossil-based plastics in its packaging system. The lower material weight also supports more efficient logistics and contributes to reduced transport-related emissions across the supply chain.
This project shows that consumer electronics packaging can meet protection and usability requirements while aligning with sustainability goals. Similar solutions can be found in our portfolio.
Packaging for consumer electronics
Consumer electronics packaging often requires a balance between protection, branding and logistics. PaperFoam® inserts are designed to work within existing cardboard packaging formats, making the transition away from plastic materials more practical.
For teams evaluating alternatives to plastic trays or foam inserts, a physical comparison is often the most effective first step. Our premium sample kit allows you to assess fit, surface quality and handling before moving into a custom design.
Considering a similar packaging transition?
If your product requires structured positioning, protection during transport and a reduction in plastic materials, a molded PaperFoam® insert can be a suitable next step. Contact PaperFoam® to discuss your packaging challenge or explore recent developments in our news section.
