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Latest news from Packaging Innovations & Empack

New lightweight, shock-resistant packaging from Amazon is now recyclable.

This month, Capri Sun ignited significant debate by urging the European Commission to reconsider its ban on plastic straws. The company contends that paper straws are “less effective” than their plastic counterparts and complicate recycling efforts. Conversely, many view plastic straws as a strong representation of the packaging waste issue.

Amazon’s scientists and engineers have partnered with Mondi to create a new paper-padded envelope featuring a shock-absorbent, paper-based lining.

These envelopes have begun to arrive at UK homes, offering protection for deliveries without any plastic content, unlike the previously used bubble wrap-lined envelopes.

Amazon emphasized that customers prefer right-sized, recyclable packaging that reduces waste and ensures their items arrive undamaged. When right-sized options aren’t available, the company optimizes the materials, type, and weight of the packaging to enhance circularity, minimize waste, and lower carbon emissions, all while maintaining safety and functionality.

This innovative design secures products during transit while effectively absorbing stress encountered along the delivery journey. Thanks to the lightweight lining, the new packaging is significantly lighter than standard cardboard boxes, reducing packaging weight by an average of 44 grams per shipment.

Additionally, these packages are designed for easy filling without wasted space, eliminating the need for extra padding materials like recyclable paper dunnage.

“Amazon transitioned away from traditional bubble-wrap padded envelopes in Europe several years ago, which posed a challenge in developing lightweight, flexible, and fully recyclable paper packaging that offers equivalent protection,” said Thais Blumer, Amazon’s European head of sustainable packaging.

“Achieving both low weight and maximum protection with a 100% recyclable paper envelope was challenging, but these envelopes are easy to pack, straightforward for customers to recycle at home, and ensure damage-free deliveries.”

The strength of the new paper-padded envelope comes from the specially engineered lightweight paper used for the outer layer, combined with a corrugated inner lining that offers durability and protection, even though it is only a few millimeters thick.

This flexible lining features multiple ridges, allowing the packaging to conform around its contents, making packing simple and quick. By preventing items from shifting during transit, the envelope protects products until they reach customers’ homes.

“Alongside Amazon, we spent several months testing our designs and assessing various padding options, including honeycomb and embossed bubble paper. Ultimately, we found that open-flute padding—a flat paper sheet attached to a sheet of ridged paper—was the best solution,” said Pedro Cuesta, a packaging engineer at Mondi.

“Developing a plastic-free padded mailer for e-commerce packaging has been an exciting collaborative effort toward a more sustainable future. We are proud that Amazon customers across Europe will soon receive their orders in these envelopes.”

The new paper-padded envelopes are offered in three sizes and can protect both single and multiple items, including everyday purchases like skincare products, health supplements, home and office supplies, and toys.

Currently, over 50% of Amazon’s European shipments utilize reduced, recyclable packaging, such as paper bags or cardboard envelopes. Since 2019, approximately 700 million shipments have used no additional packaging at all through Amazon’s Ships in Product Packaging program.

Amazon has reported a 43% reduction in packaging weight per shipment since 2015, equating to more than 3 million metric tons of packaging materials saved.

By reducing packaging, Amazon can fit more packages into each delivery van, resulting in fewer trips and helping the company move closer to its goal of achieving net-zero carbon operations by 2040.

Read the full story on Packaging News