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RRD will highlight innovations that optimize sustainability and efficiency, including its new fully recyclable VersaPac™ FastTrack Paper Mailer, at PACK EXPO International 2026, Booth W-44020. Joe Schewe, Director, Structural Design for Packaging at RRD, will also host an Innovation Stage Session on RRD’s collaboration with quip, an oral care brand, to reduce material and freight costs by 50% for its Rev Oscillating Toothbrush Packaging.
Peel, Seal & Recycle
RRD’s new VersaPac™ FastTrack Paper Mailer is curbside-recyclable and engineered for high-velocity automation. Equipped with a proprietary paper-based peel-and-seal tear strip, the paper mailer offers critical advantages:
- Eliminates the need for plastic films and silicone-coated poly strips, the industry norm.
- Complies with California SB54 plastic reduction regulations.
- Shippers can leverage the mailer to avoid carrier dimensional weight surcharges and Extended Producer Responsibility (EPR) penalties.
Plastic-free Design that Cuts Freight Costs in Half
In collaboration with RRD, quip introduced a 5-phase approach to implement a bold redesign for their Rev electric toothbrush, reducing freight costs by 50%. While prioritizing a premium unboxing aesthetic, RRD helped quip replace a plastic tray with a molded pulp paper alternative for the modern, rounded-corner design that was named PPC’s Package of the Year in 2025.
Attendees can learn how the companies worked closely over five generations of designs to achieve significant gains for quip:
- 25% material reduction with space-saving footprint reducing number of parts,
- 20% reduction in assembly time with fewer SKUs to manage,
- and a 30% reduction in overall costs.
Learn more at RRD’s Innovation Stage session, “Award-winning Sustainable Redesign: How a Leading Oral Health Brand Stands out at Retail,” at Innovation Stage 3 (N-4585) on Tuesday, Oct. 20 at 2:30 p.m. CT.
“Packaging directly impacts how a product performs in the market, moves through the supply chain and is ultimately experienced by the consumer,” said Joe Schewe, Director of Packaging Design at RRD. “At PACK EXPO International, our focus is demonstrating how material selection, structural engineering and manufacturing efficiency help brands manage costs, satisfy regulations and keep fulfillment operations running smoothly.”
Both examples of RRD’s innovation address the strong demand for widely recyclable, practical packaging. In RRD’s upcoming Consumer Packaging Report, 59% said they’d most like to see brands make packaging 100% recyclable when making a switch to advance sustainability. Fifty-three percent preferred brands to remove excess material like extra boxes, inserts, plastic wrap and empty space.
Visit RRD at Booth W-44020 during PACK EXPO International at McCormick Place in Chicago from October 18-21, 2026. For more information on RRD’s packaging capabilities, visit rrd.com/integrated-packaging.
