Heavy-Duty Corrugated Box Packaging Is Widely Used In The Photovoltaic Industry

Background:

With the growing global demand for renewable energy, the photovoltaic industry is experiencing unprecedented development opportunities. However, the transportation and storage of photovoltaic modules place extremely high demands on packaging materials: ensuring product safety during long-distance transport while also balancing environmental protection, cost, and operational efficiency. While traditional wooden packaging offers strong load-bearing capacity, it suffers from high costs, heavy weight, difficulty recycling, susceptibility to moisture, and the need for fumigation. It is no longer able to meet the dual needs of photovoltaic companies for a green supply chain and cost reduction and efficiency improvement.

Against this backdrop, we leveraged our expertise in paper packaging research and development, drawing on cutting-edge paper packaging technologies from Japan and Germany, to develop heavy-duty corrugated cardboard packaging specifically for the photovoltaic industry. This alternative to wood has now been widely adopted, and several listed Chinese photovoltaic companies have become our key strategic partners.

Challenges and Opportunities:

XX Group, a leading Chinese photovoltaic module manufacturer (hereinafter referred to as "X Group"), faced the following challenges in 2023:

1. High transportation costs: The heavy weight of wooden crates led to low transportation efficiency and high freight rates.

2. High environmental pressure: Customers have higher requirements for green packaging, and wooden crates do not meet sustainable development goals.

3. Low operational efficiency: Wooden crates require manual assembly and disassembly, making recycling inconvenient and impacting warehousing and shipping efficiency.

4. High product protection requirements: Photovoltaic modules are high-value, fragile products that need to be protected against shock, moisture, and pressure during transportation.

5. Against this backdrop, Tongwei decided to partner with our company to explore the feasibility of replacing traditional wooden crates with heavy-duty corrugated cardboard boxes.

Solution:

X Group, in collaboration with our company, jointly developed a heavy-duty corrugated box packaging product specifically designed for photovoltaic modules. It features the following core features:

1. High-Strength Structure: Utilizing seven layers of AB corrugated cardboard, combined with honeycomb cardboard and reinforced corner protection, a single box can support over 500kg.

2. Cushioning Protection: Built-in EPE foam and paper interlayers effectively absorb transport shock and protect module corners from impact.

3. Environmentally Friendly: The box is 100% recyclable and complies with EU ROHS and REACH environmental standards.

4. Lightweight Design: Compared to wooden boxes, it is approximately 40% lighter, significantly improving loading efficiency and reducing transportation costs.

5. Automation Compatibility: Standardized box specifications allow for compatibility with automated packaging lines and turnover equipment, improving operational efficiency.

6. Foldable and Recyclable: Empty boxes can be folded and recycled, reducing return transport volume by 70%, significantly reducing recycling logistics costs.

Results and Benefits:

In addition, X Group has reduced its annual wood use by approximately 1,200 tons, equivalent to reducing deforestation by approximately 30 mu (approximately 1,000 acres), earning it significant points in its ESG report.

Conclusion:

The successful application of heavy-duty corrugated cardboard in the photovoltaic industry is more than just a simple replacement of packaging materials; it also represents a significant manifestation of the manufacturing industry's transformation toward a green, intelligent, and efficient future. With the advancement of the "dual carbon" goals, not only the photovoltaic industry, but also various industries that use wood packaging for loading and shipping, such as machinery, chemicals, auto parts, electric vehicles, and motorcycles, will achieve a win-win situation of cost reduction, efficiency improvement, and sustainable development through environmentally friendly paper packaging. X Group's practice provides a replicable and scalable model for the industry and opens up new growth opportunities for technological innovation in the packaging industry.