Right-sized e-commerce packaging with e-Seal
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From oversized to right-sized packaging
E-commerce packaging has traditionally relied on a range of standard box sizes. While simple and cost-effective, this often means shipping products in boxes that are larger than necessary, with empty space filled using additional packaging materials. This can include plastic-based materials such as bubble wrap, adding unnecessary material and plastic waste to each shipment.
The result is more material, more waste for the end customer and packages that take up unnecessary space during transport. It is also likely to create a poor unboxing experience when a small product arrives surrounded by excessive packaging.
But what if packaging could instead be made to fit each order – in a simple, efficient and cost-effective way?
e-Seal combines corrugated cardboard with automated packing technology to create right-sized packages around the products being shipped, reducing empty space and unnecessary material while enabling an efficient, automated packing process.
What is e-Seal?
e-Seal is a paper-based packaging solution developed for direct-to-consumer e-commerce. Instead of selecting from pre-sized boxes, businesses create packaging around each individual order as part of their own packing process.
The single-face corrugated cardboard is supplied on rolls and wraps closely around the products. Its integrated cold-seal technology allows the material to bond to itself under pressure, closing the package without separate packing tape.
The corrugated structure provides cushioning and protection against impacts and other damage during handling and transport. Because the package is formed closely around the contents, there is minimal empty space and no need for additional void-fill material.
The result is a compact, protective and right-sized package made from sustainable material.
How does the packing process work?
The e-Seal system combines our corrugated packaging material with automated packing technology from e-motions.
The packing process works as follows:
Products enter the packing process and a camera detects the contents of the order.
The required amount of corrugated material is automatically determined based on the products being shipped.
The material wraps around the order, creating a package closely fitted to its contents.
The package seals under pressure using the material's integrated cold-seal functionality, without the need for separate tape.
The shipping label is applied, and the package is ready for dispatch.
This allows businesses to produce right-sized packages directly within their own operations through an efficient, automated process with minimal unnecessary material use.
What products are suitable for e-Seal?
e-Seal is particularly well suited to smaller e-commerce products and orders where compact, protective packaging can replace conventional boxes and additional void fill.
Typical applications include:
Books and consumer goods – books, accessories and other smaller products
Cosmetics – skincare jars, cream tubes and make-up products
Vitamins and supplements – bottles, tubs and sachets
Pharmacy and healthcare products – medicine cartons, ointment tubes and other healthcare products
Tobacco and nicotine products – snus tins, nicotine pouch containers and tobacco packs
The compact format can also increase the likelihood of packages fitting through the end customer's letterbox.
Made for your products and designed for your brand
Different colours and printing options make it possible to add your logo, branding or message directly to the packaging.
This creates a packaging solution that fits and protects the product while strengthening your brand and creating a consistent, high-quality experience from packing to unboxing.
Why choose right-sized e-commerce packaging?
Use less packaging material
Each package is formed around the contents of the individual order, reducing empty space and unnecessary packaging. This also eliminates the need for additional void-fill materials.
Automate and simplify packing
Automated packing combined with the material's integrated cold-seal functionality creates an efficient packing process with minimal manual handling. The package is formed and closed within the same process.
Protect products during shipping
The corrugated structure provides cushioning and protection against impacts and other damage during handling and delivery.
Reduce packaging and transport costs
Using the right amount of material for each order can reduce both material consumption and waste from the packing process. More compact packages are also likely to take up less space during transport, creating opportunities for further cost efficiencies.
Create a better unboxing experience
Nobody wants to receive a small product in an unnecessarily large box.
Packaging formed around the contents creates a compact and considered delivery experience, with less excess material for the customer to handle and recycle. For suitable products, the smaller format can also make letterbox delivery possible.
Support the move towards right-sized packaging
Packaging regulation is increasingly focused on reducing unnecessary packaging and empty space. The EU Packaging and Packaging Waste Regulation (PPWR), for example, introduces requirements aimed at packaging minimisation and limiting unnecessary empty space.
Right-sized solutions such as e-Seal help businesses prepare for this direction by using packaging that is proportionate to the products being shipped.
Packaging with sustainability in mind
e-Seal combines right-sizing with fibre-based materials to reduce unnecessary packaging and support a more circular use of resources.
Right-sized for every order – using only the amount of packaging needed and reducing empty space and the need for additional void fill.
Easy to recycle – the complete package can be sorted and recycled with ordinary paper and cardboard, with no material separation required.
Less space during transport – compact packages can improve transport efficiency compared with oversized boxes.
Efficient material use in production – automated right-sizing helps minimise material waste during the packing process.
Together, this means less unnecessary material, less empty space and a packaging solution designed to keep fibre-based materials in circulation.
Material and packing technology working together
The e-Seal solution combines two elements: Ryleon's corrugated packaging material and e-motions' automated packing technology.
Ryleon's business unit Kinnareds supplies the specialised corrugated material on rolls, with flexible production capabilities supporting both shorter runs and larger volumes. e-motions provides the equipment that automatically forms and seals the material around each order.
Together, the material and technology enable businesses to produce protective, right-sized e-commerce packaging directly within their own operations.
Take the next step towards right-sized e-commerce packaging
If you are looking to reduce empty space, material use and manual handling while creating compact, recyclable e-commerce packaging, e-Seal provides an efficient solution for automated, right-sized packaging.
Contact us to discuss your products, packing volumes and requirements, and we can help you evaluate the right solution for your operation.
About Ryleon
Ryleon is a European company specialising in sustainable protective packaging and authenticity solutions. With sites across Europe, we combine expertise in moulded fibre, corrugated cardboard and other sustainable materials to create packaging that protects products throughout the supply chain. Our authenticity solutions help safeguard product integrity and provide traceability. Together, we help customers solve packaging and security challenges while transitioning to more sustainable alternatives.
Protecting what matters – our customers’ products and the world we live in.
