When the world went into lockdown during the COVID-19 pandemic, online shopping became a lifeline. From groceries to lifestyle products, everything was just a click away. Yet, this convenience came with a hidden cost: a surge in packaging waste. Plastic-based materials such as bubble wrap, air pillows, and film wraps dominated shipments, leaving behind a mounting environmental burden.

Studies reveal that online shopping generates nearly five times more packaging waste compared to traditional retail. In Europe alone, pandemic-driven e-commerce activities added more than 11,000 tons of plastic waste. The challenge is also evident in the case of SWANZ, a company producing stainless steel bottles with porcelain lining. Despite using multiple protective layers like foam and bubble wrap, damage still occurred, resulting in almost 4% of online sales being returned in 2024.

Recognizing this pressing issue, the industry collaborated with BINUS ASO School of Engineering to mentor students from the Product Design Engineering program. Together, they explored sustainable packaging innovations designed to reduce bubble wrap usage while ensuring strong product protection.

To tackle this challenge, Prichia Meidina, a student of the Product Design Engineering program at BINUS ASO School of Engineering, developed a sustainable packaging solution with a unique approach. By integrating Origami Engineering with Kansei Engineering, she transformed consumer needs and emotions into concrete design specifications. The result was a packaging structure that is not only protective but also flexible, adaptable, and environmentally responsible.

Under the supervision of her academic advisor, Ir. Yosica Mariana, S.T., M.T., IPU., ASEAN Eng., and in collaboration with industry mentor Li Jun Hui Kenneth, B.Acc, the packaging solution was successfully developed. A prototype was produced and is expected to be adopted by industry to meet its practical needs, paving the way toward more sustainable and innovative packaging practices.

Design Concept: Kresling Origami

At the core of this innovation is the Kresling Origami technique—a folding pattern that allows the packaging to expand and contract with ease. This distinctive feature makes the design:

  • Adjustable to accommodate various product sizes
  • Eco-friendly by reducing dependence on bubble wrap
  • Space-efficient in storage and shipping when folded
  • Protective during drop tests, with potential for further optimization under certain conditions

Impact and Future Expectations

Beyond fulfilling immediate packaging needs, this innovation demonstrates the significant role of academia–industry collaboration in creating impactful solutions for real-world challenges. By bridging theoretical knowledge from the university with practical insights from industry, the project not only produces a functional prototype but also sets a precedent for how design engineering can contribute to sustainability transitions. The integration of Origami Engineering and Kansei Engineering illustrates how creative design approaches can be systematically translated into eco-friendly alternatives that reduce reliance on plastic-based packaging. Moreover, the initiative directly supports Sustainable Development Goal (SDG) No. 12: Responsible Consumption and Production, aligning with the global call to minimize waste and promote responsible resource use. In doing so, it encourages industries to move beyond short-term efficiency and adopt solutions that combine functionality, sustainability, and aesthetics—ultimately paving the way for a greener, more resilient future in packaging design.

Penulis:

  • Ir. Yosica Mariana, S.T., M.T., IPU., ASEAN Eng.
  • Prichia Meidina
  • Li Jun Hui Kenneth, B.Acc.