OnePack — One Box for Shelf and Shipping
Why does e-commerce packaging need two boxes when one will do?
The Opportunity
E-commerce packaging is inherently wasteful by design. A product sits in retail packaging, which sits inside a shipping box, which sits inside a delivery bag. Every layer adds material, cost, and waste. The challenge was to collapse that stack into a single format — one pack that protects on the shelf and survives the delivery network.
The Solution
We developed OnePack, a folding format inspired by origami principles. The integrated closure mechanism locks the pack for shipping without an outer box. One structure serves retail display and e-commerce fulfilment. The design cuts total material use by over 50% — not through thinner walls or weaker board, but by eliminating an entire layer of packaging from the system.
The Impact
OnePack removes the outer shipping box from e-commerce entirely. Fulfilment centres pack one item instead of two. Consumers open one box instead of two. And material use drops by half — without compromising the product inside. The format has been validated for protection performance and is ready for pilot deployment.
PSL supports packaging development for retail and distribution, balancing structural performance, material use and operational requirements.