Indian Packaging Summit 2026: Nilkamal’s BubbleGuard targets returnable packaging, cost savings in transit

Siddhartha Gijare, deputy business head, Nilkamal presented BubbleGuard as a high-strength, returnable packaging material with applications across automotive, FMCG and consumer durables, highlighting its role in reducing material consumption and transit damage.

Gijare positioned BubbleGuard within the shift from single-use to reusable systems. “Traditional packaging like wood and corrugated has limitations, especially with single-use and sustainability pressures,” he said, adding that industries are increasingly exploring returnable formats.

He described BubbleGuard as a structured plastic sheet with a layered design. “It has a three-layer structure with a circular honeycomb core,” he said, noting that this enables “one of the highest strength-to-weight ratios” among packaging materials. A key differentiator is flexibility. “Solid plastic cannot be folded, but this can,” he said, referring to its use in pallet sleeve systems. “This allows efficient return logistics and reduces transport volume.”

Gijare highlighted its role in automotive supply chains. “Returnable pallet sleeve systems are widely used in automotive,” he said, explaining that foldable designs reduce reverse logistics costs. “Multiple trucks going forward can return in one truck.”

He added that BubbleGuard replaces heavier materials in such systems. “Earlier, sleeves were made of solid plastic or wood. Now we use BubbleGuard, which is lighter and reusable,” he said.

Beyond automotive, he pointed to underutilised potential. “FMCG and consumer durables have hardly explored this. There is a long way to go,” he said, estimating that adoption remains limited despite clear benefits.

On cost, Gijare acknowledged the upfront investment. “Initial cost is higher,” he said, but emphasised lifecycle value. “If you buy wooden or corrugated separators four times a year, BubbleGuard may be needed only once.” He shared performance outcomes from case studies. In one automotive application, “customers achieved nearly three times return on packaging investment,” he said, attributing this to reuse and reduced damage.

In an FMCG case involving edible oil transport, he said, “Wastage reduced from around 0.9% to 0.08%,” after switching to BubbleGuard separator sheets. “Even a small reduction in product loss offsets packaging cost.”

Gijare also highlighted versatility. “It can be used for partitions, wraps, pallet sleeves and protective applications,” he said, noting use cases in metals, flexible packaging and industrial goods. He linked the material to sustainability metrics. “It reduces material consumption, improves logistics efficiency and lowers landfill waste,” he said, adding that the product aligns with “reduce, reuse and recycle” principles.

However, he stressed that adoption depends on mindset shift. “This is a long-term investment,” he said. “You cannot evaluate it on a per-shipment basis.” Summing up, Gijare said, “BubbleGuard has only tapped a fraction of its potential,” positioning it as a scalable solution for returnable packaging systems across industries.