Procter & Gamble (P&G) has developed an innovative e-commerce packaging solution called Versafill, which has been nominated for the Sustainability Awards 2025 in the Commercialized E-commerce category. Versafill is a 100% recyclable paper-based honeycomb-like structure that adapts to a product’s shape by pressing it against the packaging, providing superior protection during transportation. The inventor, Li Kun, credits the principles of biomimicry, drawing inspiration from the strength, lightness, and space efficiency of honeycombs in nature.
What sets Versafill apart is its ability to seamlessly blend material science with mechanics and structure, creating a superior unboxing experience while reducing material usage by approximately 85% during storage and transportation. This reduction in material leads to cost savings and emissions reduction. The packaging is made from recyclable materials, making it a more sustainable option.
The innovation has been well-received by the industry, with Versafill earning a Platinum win for the 35th Dow Packaging Innovation Awards. A consumer survey conducted during the pilot launch found that 95% of consumers ranked the unboxing experience with Versafill as better than before. To further expand its use, the team has open-licensed the Versafill package to suppliers. Additionally, they have developed Versafill 2.0, which cuts costs by 50-80% compared to the original version and is made from recycled paper, making it an even more affordable and sustainable option.
The development of Versafill has been a significant step forward in packaging sustainability, addressing key challenges in e-commerce packaging such as safeguarding goods during shipping, reducing costs, and enhancing sustainability. The team’s commitment to ongoing development and commercialization is expected to have a positive impact on the industry, with a mass launch of Versafill 2.0 expected in the near future. As the packaging industry continues to evolve, innovative solutions like Versafill are likely to play a key role in reducing waste and promoting sustainability.