UK-based Mondi has collaborated with Polana Bikes to introduce a recyclable, paper-based packaging system for transporting and storing premium bicycles.
The offering replaces the Polish bicycle manufacturer’s previous cycle packaging, which relied on plastic materials.
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Polana Bikes production manager Miłosz Pytel stated: “For years, even premium bikes were shipped in basic corrugated boxes with little attention to detail. The current market, however, demands more – both in terms of sustainability and customer experience.”
The new solution was developed after gathering operational feedback from Polana Bikes’ production facility, where bicycles from several premium brands are prepared for shipment each day.
The development process focused on some key areas: improving the customer unboxing experience, cutting down the use of non-paper materials such as foils, foam and zip ties, and improving stability during transport to reduce the risk of damage.
The jointly developed system consists of three core components.
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By GlobalDataThe first is a main corrugated box fitted with customised paper inserts, allowing bicycles to be placed into the packaging from above.
This design is intended to improve efficiency and consistency along the packing line.
The bicycle frame is secured at the base before the top section of the box is added.
The second component is the ProtectorBAG for bicycles, a pre-made protective paper bag that can be recycled in standard paper mills across Europe.
It is designed to protect parts including handlebars, frames, front wheels and saddles from scratches, punctures and dust during transport and storage.
The third element involves the use of recycled plastic locks, which enable the boxes to be opened and closed multiple times.
This allows the packaging to be reused for storage by customers and bicycle retailers.
The packaging system combines expertise from Mondi’s corrugated packaging and protective paper bag teams and was designed to meet the specific production and logistics needs of Polana Bikes.
The initiative forms part of Polana Bikes’ efforts to cut plastic waste from its packaging operations while maintaining secure transport and consistent handling performance.
ProtectorBAGs business developer Isabella Szymanski added: “It’s been fantastic working on this project and seeing it come to life, especially as the combination of the ProtectorBAG and a corrugated solution creates a powerful, more sustainable packaging. This nicely highlights our shared commitment to the environment while creating premium packaging.”
