A Finnish manufacturer of electric cargo bikes was preparing to scale internationally — but their existing domestic packaging setup was holding them back. By replacing a pallet + stretch film method with Eltete TPM’s carton-based Cargo Box, the company improved transport efficiency, reduced costs, and strengthened product protection across long distance shipments.
This case study describes the challenge, solution, and results.
Customer Background
The customer manufactures 150 kg electric cargo bikes designed for urban delivery and mobility services. Their domestic packaging used a wooden pallet wrapped with stretch film, which worked perfectly for short distance shipments within Finland.
However, as they began preparing for international transport, they needed a packaging solution capable of:
- Longer journey protection
- Better use of container and truck space
- Reduced cost per unit
- Simplified handling for dealers abroad
- More sustainable material choices
Initial Packaging Setup
Domestic solution: pallet + stretch film
The existing method had advantages for short-haul transport, but when scaling globally, several limitations emerged:
Key issues:
- Limited stackability
Only one unit could be transported per pallet footprint, wasting valuable vertical space. - Poor container and truck utilization
Space above each pallet remained unused, increasing cost per shipped unit. - Higher risk of handling damage
Stretch-film-secured products were more exposed during long international routes. - Extra assembly work at destination
Bikes required more preparation before being ready for dealers. - Sustainability considerations
Stretch film and mixed-material packaging generated waste and increased environmental impact.
To support global growth, a more efficient, protective, and sustainable approach was required.
Packaging Requirements for International Shipping
The manufacturer needed a packaging solution that ensured:
- High stackability
- Space-efficient container loading
- Improved product protection
- Lower transport cost per unit
- Quick, simple assembly for packers
- Reduced work for dealers
- Recyclable materials with no return logistics
The Eltete TPM Solution: Carton-Based Cargo Box Concept
Eltete TPM proposed a solution combining:
- A stable wooden pallet (customfitted)
To support the product weight and provide a solid base.
- The carton-based Cargo Box
Made with strong, laminated board engineered for:- Vertical strength for double stacking
- Full enclosure for added protection
- Lightweight yet durable structure
- Quick assembly without tools
- Flat-packed components requiring minimal storage space
The Cargo Box creates a rigid, protective shell around the product while allowing two fully loaded units to be stacked securely.
Testing and Validation
Before full implementation, the new packaging was tested in real international shipments.
The tests confirmed:
- Stable double stacking
- Reduce risk of damage during transport
- Faster packing times (no tools to assemble the Cargo Box)
- Dealer assembly time significantly reduced (e-Bikes delivered almost fully assembled)
- Positive feedback from all handling points
The new concept met or exceeded expectations in all key areas.
Results
- Improved Product Protection
The enclosed Cargo Box shielded the bikes from shocks, dust, and handling impact.
- Lower Transport Costs
Double stacking and better container utilization reduced cost per shipped unit.
- Higher Space Efficiency
Optimized packing allowed more products per shipment — improving both truck and container loads.
- Faster, Easier Handling
The lightweight components were easy to store, handle, and assemble.
- Reduced Work at Destination
The bikes arrived almost fully assembled, reducing preparation time for dealers.
- Sustainability Benefits
The Cargo Box is fully recyclable and eliminates the need for return logistics — supporting the manufacturer’s sustainability goals.
Why Carton-based Cargo Box Made the Difference
Many packaging materials are strong — but strength alone is not enough.
Transport efficiency comes from a packaging design matched to the product, the logistics chain, and the business model.
In this case, the combination of a stable wooden pallet and a fiber-based Cargo Box delivered:
- Higher load efficiency
- Better protection
- Lower environmental impact
- Simpler operations
- Reduced overall logistics costs
Explore Cargo Box
If you want to improve transport efficiency, reduce costs, or strengthen protection for export shipments, our Cargo Box solutions are designed to support both performance and sustainability.
👉 Learn more about Cargo Box
👉 Contact our team for a consultation
About Eltete TPM
Eltete TPM is a global supplier of fiber‑based transport packaging solutions designed to reduce waste, replace non‑recyclable materials, and support truly sustainable logistics.
Our philosophy — 3R-Reduce. Replace. Recycle. — guides every solution we create, from lightweight structural components to complete export‑ready packaging systems.
With over 50 years of manufacturing experience and a strong environmental focus, we help companies improve transport efficiency while lowering their environmental impact.
