Mondi and Polish bicycle manufacturer Polana Bikes have developed a recyclable paper-based packaging system designed to protect premium bicycles during transport while reducing plastic waste. The solution, developed through close collaboration between the two companies, replaces traditional plastic-heavy packaging with a corrugated cardboard structure and tailored paper components.
The project was driven by three main requirements: enhancing the customer unboxing experience, reducing plastic content, and improving transit stability. “When we deal with a premium brand, the unboxing experience is extremely important,” said Miłosz Pytel, Production Manager at Polana Bikes. “Our previous packaging wasn’t always up to the task – bikes would sometimes shift during transit and get damaged.”
The packaging consists of a new corrugated box structure with custom paper inserts that hold the bike frame securely in place. The bike is loaded from above into the packaging, streamlining the packing process and improving consistency on the production line.
A key component is the ProtectorBAG – a pre-made, recyclable paper bag designed to protect individual bike parts such as frames, handlebars, and wheels from scratches and dust. According to Mondi, the bag is recyclable in standard paper waste streams across Europe.
Additionally, the box includes recycled plastic locks that allow it to be reused for storage and further transport. Dawid Galusinski of Mondi Corrugated Solutions emphasized the importance of reusability: “The important thing was that the bike could be packed and unpacked easily. We also wanted the customer to be able to reuse the box.”
The new packaging is now in use at Polana Bikes’ facility and has received positive feedback from both production staff and end users. Some retailers have even shared unboxing videos online, highlighting the packaging’s protective qualities and efficient design.