How Whitecroft Lighting eliminated 100,000 cardboard cartons with smart reusable packaging

Whitecroft Lighting, a leader in sustainable lighting solutions and a Fagerhult Group company, faced a significant challenge in their supply chain operations. As a company committed to circular design principles and science-based net-zero targets, they needed to address the environmental impact of single-use packaging while maintaining efficient logistics across their UK operations. 

The key issues were:

• Excessive packaging waste: Thousands of cardboard cartons were being used and discarded for every major project 

• High waste management costs: Single-use packaging was creating substantial disposal expenses on construction sites 

• Limited visibility: No way to track reusable packaging assets across multiple project locations 

• Circular economy goals: Whitecroft’s commitment to reducing virgin materials by 80% by 2030 required innovative packaging solutions 

Traditional single-use packaging was not only environmentally unsustainable but also operationally inefficient, particularly for large-scale projects like the Fife Learning Campus where lighting products needed to be delivered safely while minimizing environmental impact. 

Whitecroft Lighting partnered with Peak Technologies, Sensolus, pdr, and Cardiff Metropolitan University to develop Geopak™ – an innovative reusable packaging solution with integrated GPS location tracking. 

How It Works

The Geopak system combines three critical elements: 

1. Connected Assets: EachGeopak container is equipped with Sensolus tracking technology, transforming standard reusable packaging into smart, connected assets that provide real-time visibility throughout the supply chain. 
2. Location Intelligence: Peak Technologies’ IoT platform captures continuous location data, enabling autonomous monitoring of everyGeopak unit as it moves between the manufacturing floor and the delivery door. 
3. Actionable Insights: The integrated system delivers operational intelligence through:

• • Real-time dashboards showing asset locations and status 

• • Automated alerts for delivery events and exceptions 

• • Utilization monitoring to optimize packaging deployment 

• • WMS/ERP integration for seamless process management 

• • AI-powered data processing for predictive analytics 

Sensolus provides the GPS tracking hardware and connectivity that makes each Geopak unit “smart,” while Peak Technologies delivers the software platform, integration capabilities, and ongoing managed services. This technology-agnostic approach ensures the solution meets Whitecroft’s specific business requirements while providing scalability for future growth. 

The Geopak solution has delivered impressive results across environmental, operational, and financial dimensions: 

Environmental Impact 

• 100,000 cardboard cartons removed from the supply chain 

• 2 tonnes of packaging waste eliminated over the project lifecycle 

• Significant contribution to Whitecroft’s goal of 80% virgin material reduction by 2030 

Operational Efficiency 

• 7,500+ kilometers traveled by Geopak units across the network 

• 310 active Geopak assets in circulation 

• Live tracking providing improved customer confidence and management visibility 

• Active deployments across Manchester, Cardiff, Edinburgh, and London 

Cost Savings 

• £6,000 saved in waste management costs at the Fife Learning Campus project alone 

• Reduced logistics complexity through better asset utilization 

• Lower handling costs compared to single-use packaging 

Enhanced Visibility 

The real-time tracking capability transformed Whitecroft’s supply chain management: 

• Complete transparency on asset location and movement 

• Improved delivery planning and scheduling 

• Better inventory management of reusable packaging 

• Data-driven decision making for logistics optimization 

Peak Technologies’ platform connects the physical Geopak assets to digital insights through a comprehensive monitoring and management system: 

• Real-Time Location Tracking: Every one of the 310 Geopak units provides continuous GPS updates via Sensolus trackers, enabling Whitecroft to monitor assets across the entire 7,500km network and ensure timely delivery to active projects in Manchester, Cardiff, Edinburgh, and London. 

• Utilization & Delivery Monitoring: The system tracks when Geopaks arrive at customer sites, dwell times at various locations, and return journeys – providing the data needed to optimize fleet size and improve delivery planning, which directly contributed to increased customer confidence. 

• Automated Dashboards & Alerts: Custom dashboards give Whitecroft instant visibility into asset status and location, while automated alerts notify the team of delivery events, extended dwell times, or assets that need retrieval – eliminating manual tracking processes. 

• Seamless ERP Integration: API-based integration with Whitecroft’s existing systems ensures packaging data flows directly into their warehouse management and planning processes, enabling the circular packaging model to operate without creating additional administrative overhead. 

This integrated approach transforms simple tracker data into actionable business insights, enabling Whitecroft to optimize their circular packaging operations continuously. 

The success of the Geopak initiative demonstrates how innovative partnerships can drive both sustainability and operational excellence. By combining Whitecroft’s circular design expertise, Peak Technologies’ IoT platform capabilities, and Sensolus’s tracking technology, the solution proves that environmental responsibility and business efficiency are not mutually exclusive. 

As Whitecroft continues to expand Geopak deployments across their operations, the real-time visibility and data insights provided by the integrated tracking solution will be essential for scaling their circular economy model while maintaining the operational agility needed in today’s competitive lighting market. 

Whitecroft Lighting is a leading provider of smart and sustainable lighting solutions, part of the Fagerhult Group. Committed to science-based net-zero targets and circular design principles, Whitecroft is pioneering innovative approaches to reduce environmental impact across their entire value chain. 

Peak Technologies is a digitally-connected supply chain and mobile workforce solutions provider with over 40 years of experience. Founded in 1981, Peak Technologies serves 12,000+ customers across transport & logistics, manufacturing, healthcare, and retail sectors, managing 600,000+ devices with a team of 1,000+ employees and 130+ field engineers. 

Sensolus provides industrial IoT tracking solutions that help companies gain visibility and control over their returnable assets, enabling data-driven supply chain optimization and supporting circular economy initiatives.