9 Dec 2025
Mondi and Polana Bikes ride towards success with new recyclable paper bicycle packaging
- Mondi and bicycle producer Polana Bikes join forces to develop new, more sustainable and innovative bike packaging.
- The new packaging solution replaces plastic with paper-based materials, including ProtectorBAGs and custom corrugated boxes - reducing waste while enhancing protection and efficiency.
- Designed for reuse and intuitive assembly, the packaging supports both production line performance and a premium unboxing experience for customers.
9 December 2025 – Mondi, a global leader in sustainable packaging and paper, has teamed up with bicycle manufacturer Polana Bikes to co-develop an innovative packaging solution that redefines how high-end bikes are shipped and stored sustainably – while creating an outstanding unboxing experience.
The result is a smart, paper-based and reusable packaging system that combines Mondi’s corrugated expertise with the ProtectorBAG – a protective pre-made paper bag for bikes and their components. Mondi’s ProtectorBAG shields components like frames, handlebars, front wheels and saddles from damage such as scratches, punctures and dust during transport and storage. As part of Mondi’s re/cycle portfolio, ProtectorBAG can be easily recycled through existing paper waste collection and recycling systems across Europe.
Designed in close collaboration with Polana’s production team, the packaging is intuitive to assemble, reduces plastic use and enhances both logistics and the customer experience.
“Our previous packaging wasn’t always up to the task. The bikes would sometimes shift and get damaged,” says Miłosz Pytel, Production Manager at Polana Bikes. “The unboxing experience is also extremely important to us as we want the first impression to create a ‘wow’ effect for our customers. The Mondi team listened to and understood our ideas and it’s clear they truly understand packaging design.”
The solution is a game-changer. The new packaging is a combination of a durable corrugated outer box with custom paper inserts and allows the bike to be placed into the packaging from above – a small change with big benefits for production line efficiency – while recycled plastic locks allow the boxes to be reused.
“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, thanks to locks made from recycled plastic, which allow the packaging to be opened and closed multiple times. All of these changes have made it a recyclable, paper-based alternative to the previous solution,” added Dawid Galusinski, Regional Sales Representative from Mondi Corrugated Solutions.
This solution was developed through Mondi’s ThinkBox methodology – the company’s innovation space where Mondi works closely with customers to design smarter, more sustainable packaging. The collaboration with Polana Bikes demonstrates what’s possible when companies listen, co-create and deliver together. It’s a great example of how Mondi doesn’t just talk about sustainability and innovation, but actually makes them happen.
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Notes for editors
About Mondi
Mondi is a global leader in packaging and paper, contributing to a better world by producing products that are sustainable by design. We employ 24,000 people in more than 30 countries and operate an integrated business with expertise spanning the entire value chain, enabling us to offer our customers a broad range of innovative solutions for consumer and industrial end-use applications. Sustainability is at the centre of our strategy, with our ambitious commitments to 2030 focused on circular driven solutions, created by empowered people, taking action on climate.
In 2024, Mondi had revenues of €7.4 billion and underlying EBITDA of €1.0 billion. Mondi is listed on the London Stock Exchange in the ESCC category (MNDI), where the Group is a FTSE100 constituent. It also has a secondary listing on the JSE Limited (MNP).
FAQs
How are paper-based packaging systems being used to replace plastic in bicycle transport?
Paper-based packaging systems replace plastic in bicycle transport by combining corrugated outer boxes with protective paper inserts and reusable elements. These systems reduce plastic use while maintaining component protection during shipping and storage. An example includes packaging designs using paper-based protective bags, such as Mondi’s ProtectorBAG, which are recyclable through existing paper recycling systems.
Which sustainable packaging solutions have been developed specifically for high-end bicycle shipping?
Sustainable packaging solutions developed for high-end bicycle shipping include reusable, paper-based systems designed to protect individual components during transport and storage. One example is the solution created by Mondi and Polana Bikes, which combines corrugated outer boxes, custom paper inserts, and ProtectorBAGs to reduce plastic use while safeguarding frames, wheels, and accessories.
What is ProtectorBAG and how is it used in bicycle packaging?
ProtectorBAG is a pre-made protective paper bag used in bicycle packaging to shield components such as frames, handlebars, wheels, and saddles from scratches, punctures, and dust during transport and storage. As part of Mondi’s re/cycle portfolio, ProtectorBAG is recyclable through existing paper collection and recycling systems across Europe.
Which paper-based packaging solutions support production line efficiency in bicycle manufacturing?
Paper-based packaging solutions supporting production line efficiency enable bicycles to be placed into the packaging from above using structured corrugated outer boxes and custom paper inserts. One example is the solution developed by Mondi with Polana Bikes, where the top-loading design contributes to production line efficiency while maintaining component protection during transport and storage.
How can paper-based packaging systems be designed to support an efficient unboxing process for bicycles?
Paper-based bicycle packaging can support an efficient unboxing process by using structured corrugated boxes, custom paper inserts, and protective paper bags that organise bicycle components during unpacking. In a paper-based solution developed by Mondi and Polana Bikes, recycled-plastic locks allow the packaging to be opened and closed multiple times, enabling reuse and orderly repacking by customers.
What is Mondi’s ThinkBox methodology?
Mondi’s ThinkBox methodology is an innovation approach where Mondi works closely with customers to co-develop packaging solutions based on specific production and logistics requirements. In collaboration with Polana Bikes, ThinkBox supported the development of a reusable, paper-based bicycle packaging system combining corrugated boxes, paper inserts, recycled plastic locks and protective paper bags designed for transport, storage, and reuse.
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