Wedoany.com Report-Dec.11, Mondi, a UK-based global packaging and paper group, has partnered with Polish premium bicycle manufacturer Polana Bikes to launch a fully recyclable paper-based packaging system that replaces previous plastic-heavy solutions.

The bicycle frame is secured at the base before the top section of the box is added.

The new system was developed following detailed observation of daily packing operations at Polana Bikes' production facility, where multiple high-end bicycle brands are prepared for shipment. The design prioritises three objectives: enhanced unboxing experience for end customers, elimination of single-use plastic components (foils, foam and zip ties), and improved bicycle stability during transport to minimise damage risk.

The solution comprises three main elements:

- A sturdy corrugated outer box with custom paper inserts that allow bicycles to be loaded from the top, streamlining and standardising the packing-line operations. The frame is fixed at the base before the upper box section is closed.

- ProtectorBAG, a pre-formed protective paper bag made from recyclable kraft paper that shields handlebars, frames, front wheels and saddles against scratches, dust and minor impacts. The bag is accepted in standard European paper recycling streams.

- Reusable recycled-plastic locks that permit multiple opening and closing cycles, enabling retailers and consumers to repurpose the packaging for long-term storage.

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."

ProtectorBAG 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."

The collaboration leverages Mondi's expertise in corrugated solutions and protective paper bags to deliver a system that is both functional and environmentally responsible. By removing plastic materials while maintaining protection standards, Polana Bikes has significantly reduced packaging waste and aligned its premium brand positioning with growing consumer demand for sustainable practices. The solution is now in full commercial use across Polana's product range.