How LEGO is Overcoming Challenges With Paper-Based Packaging
Switching to paper-based bags for LEGO sets might seem simple, but the global toy maker has highlighted the challenges involved in making the change.
So far, LEGO has tested 180 types of paper. Despite the complexity, all its factories have now begun production using the new bags.
LEGO CSO Annette Stube said: “I’m excited to share our progress moving to paper-based bags in LEGO sets - taking out single-use packaging.
“We are not finished yet, but our team of clever and creative colleagues are working hard globally to make this important transition happen.”
The paper project: progressing fast
LEGO’s LinkedIn shared news of its “great thinking inside and outside the box”.
It said: “We’re currently switching to paper-based bags in our LEGO sets as part of our commitment to reduce single-use plastic from our packaging.
“This transition has been a challenging yet important part of our sustainability journey.”
The company outlined key progress:
- 180 paper types tested
- All LEGO factories worldwide have begun production
- Paper bags now used in more sets across Europe and Asia, with rollout in the Americas soon
- New bags are strong, fold easily and “will not tear in transit”
- Certified recyclable in the EU, US and Canada
Challenges surrounding paper-based packaging
The sheer amount of time and effort required to produce the right paper-based packaging for LEGO is remarkable.
As LEGO explains: “Packing LEGO bricks into paper-based bags might sound simple but the reality is more complex.
“We tested around 180 different paper types and formats to find the right solution.
“We had to find a bag that would not compromise the high standards LEGO fans expect from us. It had to withstand the manufacturing process and not tear or damage on the way from the LEGO factory to LEGO builders.”
It adds: “Paper is more sensitive than plastic to changes in humidity, so it was important to find a material that can be made and used in all our factories, whether in a hot, humid climate or a colder one.”
LEGO also tested 15 different prototypes, with hundreds of children and parents trying various shapes, materials and graphic designs.”
The move to paper-based bags is likely to have an intended consequence – making the kits even more fun.
“Paper has the unintended benefit of being more enjoyable to unwrap, because while clear, single-use plastic bags allow builders to see the contents, we discovered in testing that children enjoyed the suspense of opening the paper-based bags.
"Our larger paper-based bags come in a shape that enables them to stand, which is particularly useful for storing loose bricks during the building process."
Building on a sustainable base
LEGO’s website explains why the change is happening.
“We’re introducing recyclable packaging across all areas of our business, from our core products to licensed products made by our partners.
“At present, 93% of our packaging by weight is made from paper, cardboard and other paper-based materials.
“We are reducing single-use plastic and introducing paper-based bags in all our LEGO sets, and are working hard to make this transition across all our factories.”
The company says its packaging is designed to provide information and protect the set inside, so no bricks go missing.
“It’s our aim that all our packaging will be made from responsibly sourced materials that are either renewable or made from recycled content and certified by the Forest Stewardship Council.”
Other forms of packaging progress
The move to paper-based bags is just one step in LEGO’s wider push for more sustainable packaging. Other efforts include:
- Using responsibly sourced materials for LEGO boxes
- Replacing single-use plastic on baseplate packaging with paper-based alternatives
- Starting the phase-out of plastic retail bags in stores worldwide back in 2020
- Swapping plastic cups in Pick a Brick stations for flat-pack paper containers
- Changing Build a Minifigure packaging from plastic to recyclable cardboard.
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