agency industrial design Lyon innovation expert functional prototype decathlon circular pack

A circular pack concept for Decathlon

01.Brief

DECATHLON

Product design

Strategic design

E-commerce generates a significant amount of single-use packaging. Decathlon wanted to develop a reusable, circular pack with up to 100 cycles, capable of integrating into its logistics flows without causing operational disruption. The work involved analyzing the interactions between stakeholders, logistics flows, and usage patterns, and then structuring an integrated solution that could fit into this system without disrupting it.

Today e‑commerce represents approximately 1.5 billion parcels each year in France, generating 375,000 tonnes of cardboard.

Sources : La poste.fr / journal Le Monde

01.To integrate into existing logistics flows

E-commerce flows are highly optimized and involve numerous stakeholders. Any change can disrupt the supply chain. This work is based on analyzing the interactions between order preparation, transport, and returns. The packaging is designed to circulate without altering existing operations.

02.
Organize a frictionless return of the pack

The return of the package is based on existing practices. The customer folds the package to postal format and drops it in a La Poste mailbox, free of charge. A permanent address and a unique code are integrated into the product. These ensure traceability and prevent losses. Upon receipt, the package is reintegrated into the logistics flow for reuse.

03.
Adjust through field testing

Tests are being conducted with Decathlon's logistics teams and their carrier to validate handling, transport, and return conditions. A major constraint has emerged: designing a format compact enough for return shipping while remaining robust enough for logistical operations. Adjustments are being made to the folding mechanism and dimensions.

04.
Designing a sustainable product

The solution comes in three textile pack formats, adapted to different types of products. The product is made from a durable, weather-resistant fabric. Two adjustable straps and a closure buckle secure the pack and serve as a support for the shipping label. The system minimizes weak points and simplifies handling. The design is then refined by in-house teams to align with existing industrial capabilities and expertise.

Results

A circular pack concept adapted to the type of Decathlon products, designed to be reused up to 100 cycles and to integrate into existing logistics and postal flows.