Packaging solutions for automotive and suppliers

FUCHSPACK develops protective packaging for automotive suppliers and OEM supply chains: form-fitting foam packaging for heavy and complex components, low-contact suspension packaging for painted and scratch-sensitive surfaces, and airbag packaging – with ESD protection on request – for sensors and electronics. We analyse your shipping logistics on site, test in our packaging lab and deliver a solution that combines product protection with packing speed.

The automotive industry depends on the reliable delivery of a wide range of high-value components: sensitive sensors and control units, plastic parts with scratch-prone surfaces, high-quality painted panels, heavy engine and transmission parts with complex geometries. Manufacturers only list their suppliers after rigorous auditing – and delist them again if quality issues persist. Transit damage counts as a quality issue.

That is why more and more suppliers are looking for protective packaging that combines precisely fitting product protection with high productivity at the packing station. This is exactly what we come to your company for: we review your shipping logistics and, together with you, develop packaging that helps safeguard your status as a listed supplier – while taking into account the requirements of the EU Packaging and Packaging Waste Regulation (PPWR) on empty space and recyclability from the outset.

What does the automotive industry demand of protective packaging?

Packaging decision-makers at suppliers are caught between supplier ratings, cost pressure and cycle times. Typical requirements we solve in automotive projects:

Zero-defect delivery Scratches on painted or polished surfaces, bent contacts or hairline cracks in plastic parts lead to complaints from the OEM – and feed straight into the supplier rating.
Heavy parts with complex geometry Engine, transmission and chassis components need packaging that takes up the weight with a perfect fit and distributes point loads – without any cutting and improvising at the packing station.
Electronics and sensors Control units, sensors and circuit boards must be protected against shock, vibration and electrostatic discharge – reproducibly, shipment after shipment.
Cycle times and mixed shipments Just-in-time call-offs leave little time at the packing station. Changing part numbers and batch sizes call for a system that copes with many formats without changeover.
Documentation and sustainability Declarations of conformity, recyclability and the 50 % empty-space rule of the PPWR are becoming part of supplier requirements. Packaging thus becomes a documentation task.

Which packaging solutions are suitable for automotive components?

From our five cushioning systems, we put together the right combination for each component group – tested in our packaging lab and at your packing station.

Foam packaging for heavy and complex components

INSTAPAK foam expands inside the box and moulds itself around engine, transmission or brake components for a perfect fit. Point loads are distributed and the part sits firmly – without cutting to size and without stocking ready-made moulded parts. For production runs with consistent geometry, we supply precisely fitting moulded foam cushions.

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Suspension packaging for painted and polished surfaces

The component is held between film and frame and touches nothing but the membrane – ideal for trim strips, bezels, mirror caps and electronics housings. The packaging is reusable and well suited as returnable packaging in the supply loop.

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Airbag packaging with ESD protection for sensors

Air-filled UNIQBAG bags enclose control units, sensors and displays in a shock-absorbing cushion; with protection against electrostatic discharge on request. Transparent, lightweight and quick to inflate – also for spare-parts and repair shipments.

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Paper cushioning and air cushions for voids and mixed shipments

For small parts, spare-parts kits and changing formats, paper cushioning and air cushion systems fill the void right at the packing station – fast, material-saving and in line with the empty-space rule of the PPWR.

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Typical components we pack for automotive

Control units, sensors and wiring harnesses
Headlights, displays and control panels
Painted panels, bezels and trim strips
Engine, transmission and chassis components
Moulded plastic parts with sensitive surfaces
Spare parts in after-sales and workshop shipments

How packaging optimisation with FUCHSPACK works

Five steps – from the on-site analysis to roll-out, with no risk to your day-to-day shipping.

On-site consultation We look at your products, packing stations and shipping routes – and record the conditions of your processes.
Development and testing in the packaging lab Together we define the protective packaging and test it with your original product.
Cost-benefit calculation Packing time, material, freight and damage – all figures in black and white as proof of success.
Trial order You receive the system including material on trial and test it in live operation.
Roll-out and update service Only once you are convinced do we close the deal. On request, we check every two years whether everything is still at its optimum.

Benefits you will want to pack!

Benefit from FUCHSPACK's dual expertise: we combine effective product protection inside the packaging with maximum efficiency in your packaging processes.

Cost-effective solutions

Inefficient packaging processes are expensive. We analyse your workflow and develop a cost-effective solution.

Update service

Packaging processes change. On request, we check every two years whether everything is still running at its optimum.

Time savings

With our solutions – even for complex geometries – improvised, home-made packaging becomes a thing of the past.

Fewer complaints

Effective product protection inside the packaging. Our solutions fit the shipped goods like a second skin.

Frequently asked questions: packaging for Automotive

Yes. We incorporate your customer's specifications (e.g. on load carriers, cleanliness, ESD or labelling) into the packaging development, test the solution in our packaging lab and document the result so that you can present it to your customer.

With low-contact systems: suspension packaging holds the part between film and frame so that the surface never touches the box. Alternatively, airbag packaging encloses the part in an air cushion. Which option is more cost-effective depends on quantity and geometry – we clarify this in testing.

For control units, sensors and circuit boards, we use airbag packaging, which we equip with protection against electrostatic discharge on request. Combined with a precisely fitting box, this creates reproducible protection across the entire supply chain.

In future, packaging will require a declaration of conformity, must be recyclable and, from 2030, may contain no more than 50 % empty space – with void fill counting as empty space. The most effective lever is a precisely fitting box, followed by a cushion with as little volume as possible. We take both into account in every automotive solution.

Request a packaging consultation for automotive

Leave us your contact details – we will get in touch personally, clarify briefly which components you ship and where the sticking points are today, and propose an appointment for the on-site analysis.

Or contact us directly: +49 (0) 21 73-916 33-0 · verkauf@fuchspack.com

For more than 30 years we have been developing protective packaging for industry and retail – with on-site consultation and testing in our own packaging lab in Langenfeld, Germany.

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