In automotive manufacturing, packaging is very important. Done badly, it chips paint and drain budgets. Done well, it speeds up builds and cuts cost. Lesters Packaging decided to change the game. The result is the AutoPak Pro, a fully recyclable, collapsible sleeve pack that handles everything from bonnets to bumper trim while reducing freight costs and carbon footprints in one go.
🎥 See AutoPak Pro in action – watch our under 2 minute video on YouTube above.
Why the Industry Needed Something New
Traditional stillages solve one problem, durability, while creating three more: dead weight, huge return freight and landfill at end-of-life. Disposable cartons flip the script: light and cheap but rarely survive a second lap. AutoPak Pro is our answer.
Versatility up front
AutoPak Pro securely locates both large exterior panels and smaller interior trim, all in the same system. Adjustable inserts cradle everything from bonnets and glass roof panels to outer trim clips. That flexibility cuts out the need for multiple pack types and the engineering hours that go with them.
Density without the dents
The clever layout maximises part count per pallet while maintaining safe clearances, so that you can ship more components per lorry without pushing damage rates through the roof.
AutoPak Pro at a Glance
Feature | What it means on the line |
Modular, secure inserts | Same sleeve handles bonnets, doors, roof panels and inner trim; swap dividers, not the whole pack. |
Collapsible & flat-packed return | Once emptied, AutoPak Pro folds flat in seconds. Return journeys reclaim up to 80% of trailer space, trimming both fuel bills and carbon footprint. |
Replaceable panels & runners | Individual parts swap out in minutes, extends life, reduces waste, lowers total ownership cost. |
Triple-wall corrugated board | Lightweight but strong: proven to shrug off forklift bumps, vibration and weather during outdoor staging. |
Delivered fully kitted | Dividers, labels and barcodes pre-fitted at Lesters, operators fill and roll, no assembly shift required. |
100 % recyclable, FSC-certified | Supports OEM sustainability KPIs and circular-economy targets without compromise on strength. |
These attributes make AutoPak Pro one of the most versatile automotive parts packaging solutions on the market, stronger, smarter, greener.
Stronger. Smarter. Greener. Built for the Road Ahead.
If you’re looking to protect parts, free up warehouse space and hit your environmental targets, it may be time to swap yesterday’s crates for a stronger, smarter, greener alternative.
Ready to upgrade your logistics? Contact us today. Let’s build a bespoke solution that keeps your parts safe, your line flowing and your sustainability targets on track.