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Driving Sustainable Development Through Packaging - a Case Study at ASSA ABLOY

Schäfers, Katharina LU and de Brouwer, Coco Catharina (2025) MTTM03 20251
Packaging Logistics
Abstract
This master thesis investigates how a manufacturing company develops and implements packaging solutions for sustainable development, using ASSA ABLOY as a case study. Focusing on the sliding door operator produced at a manufacturing plant in Eastern Europe, the study explores the environmental and economic impacts of packaging throughout its life cycle and the internal packaging innovation process. The research adopts an embedded single-case study design supported by qualitative data from interviews, workshops, site visits, and prototyping.
Key challenges identified include reliance on fossil-based packaging material, oversized packaging dimensions, and limited organizational packaging innovation. Two alternative packaging concepts were... (More)
This master thesis investigates how a manufacturing company develops and implements packaging solutions for sustainable development, using ASSA ABLOY as a case study. Focusing on the sliding door operator produced at a manufacturing plant in Eastern Europe, the study explores the environmental and economic impacts of packaging throughout its life cycle and the internal packaging innovation process. The research adopts an embedded single-case study design supported by qualitative data from interviews, workshops, site visits, and prototyping.
Key challenges identified include reliance on fossil-based packaging material, oversized packaging dimensions, and limited organizational packaging innovation. Two alternative packaging concepts were developed and evaluated; one focusing on fossil-free materials, and another optimizing the package’s size and weight. The latter achieved a 42% reduction in packaging costs and 34% decrease in emissions, demonstrating the feasibility of the sustainable redesign.
In parallel, the thesis assesses ASSA ABLOY’s packaging innovation process, revealing strong technical capabilities but critical gaps in leadership, strategic direction, and resource allocation. A strategic roadmap is proposed to align the company’s packaging practices with upcoming regulations such as the EU Packaging and Packaging Waste Regulation (PPWR) and the Deforestation Regulation, while supporting long-term sustainability goals.
By integrating life cycle thinking, prototyping, and organizational analysis, the thesis offers a comprehensive framework to advance sustainable packaging in manufacturing. The findings highlight that technical innovation must be accompanied by organizational alignment and commitment to achieve sustainable progress. (Less)
Popular Abstract
When you think about sustainability, cardboard boxes and plastic foam might not be the first things that come to mind. But for global manufacturing companies, packaging is part of the journey toward a more sustainable future. Our master thesis explores how ASSA ABLOY, a global leader in access solutions, can reduce emissions and costs by rethinking the way it packages sliding door operators made at its Eastern European plant.
We identified three major challenges: the use of fossil-based plastic materials, oversized packaging, and a lack of structure in managing packaging innovations. To address part of these, we developed two new packaging concepts.
The first replaces fossil-based packaging for wood foam, a renewable and recyclable... (More)
When you think about sustainability, cardboard boxes and plastic foam might not be the first things that come to mind. But for global manufacturing companies, packaging is part of the journey toward a more sustainable future. Our master thesis explores how ASSA ABLOY, a global leader in access solutions, can reduce emissions and costs by rethinking the way it packages sliding door operators made at its Eastern European plant.
We identified three major challenges: the use of fossil-based plastic materials, oversized packaging, and a lack of structure in managing packaging innovations. To address part of these, we developed two new packaging concepts.
The first replaces fossil-based packaging for wood foam, a renewable and recyclable alternative. The second optimized the size and shape, reducing both weight and volume. The result: a 34% reduction in emissions and a 42% cut in packaging costs, showing that sustainable design, can lead to both environmental and economic savings.
But technical improvements are only half the story. We also looked at how ASSA ABLOY manages packaging development internally. While technical tools exist, we found two key gaps, leadership and resource allocation, that limit packaging innovation. To support progress, we proposed a strategic roadmap including aspects such as the setting of specific packaging-specific goals, resource allocation, the development of a packaging-specific strategy, and taking into account upcoming packaging regulations.
Our results are case-specific, but we believe they are relevant for other manufacturing companies in a similar position. Ultimately, our findings highlight that sustainable packaging is not just a design challenge, it is the result of integrating both product development and innovation processes. The complete thesis can be found in the published report “Driving Sustainable Development Through Packaging – a Case Study at ASSA ABLOY” by Coco Catharina de Brouwer and Katharina Schäfers at The Faculty of Engineering – LTH, Lund University. (Less)
Please use this url to cite or link to this publication:
author
Schäfers, Katharina LU and de Brouwer, Coco Catharina
supervisor
organization
course
MTTM03 20251
year
type
H2 - Master's Degree (Two Years)
subject
keywords
Packaging, Sustainable Development, Prototyping, Packaging Innovation Process and Packaging Life Cycle
language
English
id
9196268
date added to LUP
2025-06-17 08:14:47
date last changed
2025-06-17 08:14:47
@misc{9196268,
  abstract     = {{This master thesis investigates how a manufacturing company develops and implements packaging solutions for sustainable development, using ASSA ABLOY as a case study. Focusing on the sliding door operator produced at a manufacturing plant in Eastern Europe, the study explores the environmental and economic impacts of packaging throughout its life cycle and the internal packaging innovation process. The research adopts an embedded single-case study design supported by qualitative data from interviews, workshops, site visits, and prototyping. 
Key challenges identified include reliance on fossil-based packaging material, oversized packaging dimensions, and limited organizational packaging innovation. Two alternative packaging concepts were developed and evaluated; one focusing on fossil-free materials, and another optimizing the package’s size and weight. The latter achieved a 42% reduction in packaging costs and 34% decrease in emissions, demonstrating the feasibility of the sustainable redesign. 
In parallel, the thesis assesses ASSA ABLOY’s packaging innovation process, revealing strong technical capabilities but critical gaps in leadership, strategic direction, and resource allocation. A strategic roadmap is proposed to align the company’s packaging practices with upcoming regulations such as the EU Packaging and Packaging Waste Regulation (PPWR) and the Deforestation Regulation, while supporting long-term sustainability goals. 
By integrating life cycle thinking, prototyping, and organizational analysis, the thesis offers a comprehensive framework to advance sustainable packaging in manufacturing. The findings highlight that technical innovation must be accompanied by organizational alignment and commitment to achieve sustainable progress.}},
  author       = {{Schäfers, Katharina and de Brouwer, Coco Catharina}},
  language     = {{eng}},
  note         = {{Student Paper}},
  title        = {{Driving Sustainable Development Through Packaging - a Case Study at ASSA ABLOY}},
  year         = {{2025}},
}