Mondi redesigns industrial packaging to eliminate bubble wrap

Mondi and heating technology manufacturer Stiebel Eltron have developed a new recyclable cardboard packaging solution that replaces conventional bubble wrap and reduces material use for industrial equipment shipments.

The redesigned packaging was created for Stiebel Eltron’s heat pump components and demonstrates how structural optimisation can improve both sustainability performance and logistics efficiency.

Instead of relying on separate protective materials, the new solution uses engineered corrugated cardboard to provide product protection during transport.

Cardboard structure replaces plastic cushioning

Industrial products often require additional protective materials to prevent damage during handling and distribution.

Traditional solutions such as bubble wrap can provide effective cushioning but introduce additional plastic components that complicate recycling and increase material complexity.

Mondi’s redesigned format replaces these elements with a fibre-based structure designed to absorb impacts while keeping the packaging within a simpler material system.

Packaging weight reduced by more than 80%

The new solution achieves a significant reduction in packaging weight compared with the previous format.

Mondi and Stiebel Eltron report that the redesign reduces packaging weight by more than 80%, lowering material consumption and reducing the amount of packaging handled throughout the supply chain.

Lower weight can also contribute to transport efficiency by reducing the overall mass moved during distribution.

Design replaces multiple components with one solution

The previous packaging system relied on several separate materials to protect the product.

The new cardboard-based design integrates protective functions directly into the structure, reducing the number of components required.

This approach reflects a wider trend in packaging engineering: replacing added protective materials with smarter structural design.

Industrial equipment creates demanding packaging challenges

Packaging for heating systems and technical components must provide strong protection against impacts, vibration and handling throughout logistics operations.

Unlike many consumer products, industrial equipment is often heavier and requires packaging capable of maintaining stability during storage and transport.

The success of fibre-based alternatives in these applications depends on achieving the right balance between strength, weight reduction and recyclability.

Recyclability improves through material simplification

Reducing the number of materials in a package can improve its compatibility with existing recycling systems.

By replacing plastic cushioning materials with corrugated cardboard, the new design creates a packaging solution based primarily on fibre.

This simplifies separation for users and supports higher-value recovery of the packaging material after use.

Packaging redesign supports logistics efficiency

The project also highlights how sustainable packaging redesign can deliver operational benefits.

Optimised structures can reduce storage requirements, simplify handling and improve efficiency throughout the supply chain.

For industrial manufacturers, these improvements can be as important as material reduction because packaging decisions influence warehouse operations, transport and product delivery.

Structural innovation becomes an alternative to material substitution

The Mondi and Stiebel Eltron collaboration demonstrates that reducing packaging impact does not always require a completely new material.

In many cases, significant improvements can come from redesigning how existing materials are used.

By replacing multiple protective components with a single engineered fibre structure, companies can reduce waste while maintaining the performance required for demanding industrial applications.

Fibre-based packaging expands into industrial markets

The project reflects a broader expansion of paper and cardboard packaging into applications traditionally associated with plastic-based protection systems.

As companies seek to reduce plastic use and improve recyclability, structural fibre solutions are increasingly being developed for heavier and more technically demanding products.

The success of these solutions will depend on continued advances in material engineering, testing and industrial-scale adoption.