10 years ago, Lovepac was given the challenge to redesign a foam pack that required ESD protection. The pack had anti-static foam, ESD bag, and black ESD corrugated. It also needed to have a vibration cushioning protection. The issue was that the product had a low value $$, but still needed protection.
We ended up replacing the foam with a corrugated suspension system and instead of all the ESD material, we ended up just using a grey shielded ESD bag that provided 100% static protection.
Over all we reduced this pack’s cost by 90% – saving the client millions of dollars per year.