Protective Mailer

Mondi and Amazon have developed an innovative paper-padded mailer for eCommerce deliveries, replacing plastic bubble-wrap padding with its shock-absorbent, fully paper-based, protective padding that is designed for circularity and recyclability.

The mailer is made entirely from paper, eliminating plastic-based bubble wrap padding, which often complicates recycling processes and results in more rejected material after recycling. By using fully paper-based materials, it ensures compatibility with European recycling systems, where fibre-based packaging already enjoys a high recycling rate. This shift from single-use plastic to paper helps increase the overall recycling rate for packaging, pushing towards the 90% target set by 4evergreen.

The design of the mailer has been optimised for recyclability from the outset – going hand-in-hand with Mondi’s and Amazon’s goal to develop packaging that is sustainable by design. The use of open-flute padding provides necessary protection for a variety of different products while remaining fully recyclable, ensuring the packaging can be processed efficiently at the end of its life.

Moreover, the lighter weight of the paper mailer compared to traditional corrugated boxes not only reduces material waste but also lowers the carbon footprint associated with transportation. Due to the lightweight lining, the package itself is much lighter than equivalent-sized cardboard boxes used by Amazon, avoiding 44g of packaging per shipment, on average. More packages can be transported per delivery vehicle, reducing the number of trips required and thus contributing to lower carbon emissions.

Finally, the collaboration with Amazon to develop this mailer demonstrates the potential for large-scale impact. As the mailer is rolled out across Europe, it sets a precedent for other companies to follow, driving industry-wide adoption of recyclable packaging solutions.

Mondi’s Protective Mailers are a groundbreaking innovation in sustainable eCommerce packaging. Designed to replace conventional padded mailers with plastic bubble inlays, these mailers are made entirely from kraft paper and open-flute material, offering a fully recyclable alternative that fits into conventional paper waste streams. This design shift aligns with the growing demand for sustainable packaging solutions and addresses a critical recyclability challenge faced by the industry with composite or hybrid solutions.

What sets these mailers apart is their unique open-flute construction. This material design provides superior cushioning and adaptability, offering a customisable fit for various product types while ensuring maximum protection during transit. Unlike traditional void fillers or bubble wraps, the open-flute padding is both resilient and efficient, reducing material use without compromising on safety.

The mailers are available in standard or custom sizes, with adjustable height to fit products securely. This flexibility minimises excess packaging, reduces shipping costs, and lowers the carbon footprint. Enhanced printability adds further value, transforming the mailers into a branding tool that strengthens customer engagement through customised messaging and designs.

By addressing key market demands—protection, recyclability, and efficiency—Mondi’s Protective Mailers respond to a growing need for sustainable packaging in the eCommerce sector. With 88% of consumers prioritising protective yet recyclable packaging, this solution bridges the gap between functionality and environmental responsibility.

Mondi’s Protective Mailers demonstrate how innovative design and material choices can redefine packaging, offering eCommerce businesses a sustainable and impactful alternative to traditional mailers.

The successful collaboration between Mondi and Amazon underscores the innovation and practicality of the Protective Mailers. In the past three years, Amazon replaced single-use plastic delivery bags with recyclable paper delivery bags and cardboard envelopes for orders shipped from its fulfilment centres in Europe. One of the products that Amazon discontinued in favour of this easily recyclable paper-based solution was a plastic-padded envelope, which used single-use plastic bubble-wrap padding. With simple yet innovative solutions, such as the paper-padded envelope, Amazon is leading the way by adopting more circular packaging solutions at scale.

https://www.mondigroup.com/news-and-insight/2024/mondi-and-amazon-team-up-to-bag-three-prestigious-sustainable-packaging-awards/

https://www.aboutamazon.eu/news/sustainability/new-recyclable-amazon-packaging-landing-on-doorsteps-in-europe-the-paper-padded-envelope

https://www.mondigroup.com/