As part of its commitment to avoiding unnecessary packaging wherever possible, Amazon scientists and engineers worked with Mondi to develop a new paper-padded envelope with shock-absorbent, paper-based lining.
The new envelopes, which have started landing on UK doorsteps, protect deliveries without using any plastic content — unlike envelopes lined with bubble wrap which had been used previously.
Amazon customers want rightsized, recyclable packaging that minimises waste and ensures damage-free delivery. When this is not an option, Amazon optimise the type, material, and weight of packaging to increase circularity, avoid waste, and reduce carbon emissions — without sacrificing safety or functionality.
This latest design is simple and effective, and designed to keep products securely in place, while at the same time absorbing stress put on the package during its journey to customers’ homes. Due to the lightweight fluted lining, the package itself is much lighter than equivalent-sized cardboard boxes, avoiding 44g of packaging per shipment, on average. They are also easy to fill without wasted space due to their greater flexibility, and the fact they don’t require additional padding materials to be added, such as recyclable paper dunnage.
“Amazon stopped using traditional bubble-wrap padded envelopes in Europe several years ago, which presented a challenge to develop light, flexible and fully recyclable paper packaging that provides the same protection,” said Thais Blumer, European Head of Sustainable Packaging for Amazon. “Achieving both low weight and maximum protection with a 100% recyclable paper envelope was not an easy task, but these envelopes are easy to pack, simple for customers to recycle at home, and enable damage-free deliveries.”
The new paper-padded envelope gets its strength from the specially engineered lightweight paper used for the outer package paired with a corrugated inner lining that provides resilience and protection, despite only being a few millimetres thick. The flexible design of this lining also features multiple ridges, allowing the packaging to fold around its contents in a way that makes it simple and quick to pack. By preventing goods from shifting inside the package, the envelope safeguards products in transit, until they arrive safely at customers’ homes.
“Together with Amazon, we spent several months testing our designs, evaluating various padding options such as honeycomb and embossed bubble paper. Ultimately, open-flute padding — a flat paper sheet attached to a sheet of ridged paper — proved to be the best solution,” said Pedro Cuesta, Packaging Engineer from Mondi. “Creating a plastic-free padded mailer for e-commerce packaging has been an exciting collaborative journey towards a more sustainable future. We are proud that Amazon customers all over Europe could soon be receiving orders in these envelopes.”
The new paper-padded envelopes are available in three sizes and can be used to protect single and multiple items. These include common everyday purchases ranging from skincare and health supplements to home and office items, as well as toys.
More than 50% of Amazon European shipments now come in reduced, recyclable delivery packaging, such as a paper bag or cardboard envelope or — in the case of 700 million shipments since 2019 — no added packaging at all through Amazon’s Ships in Product Packaging programme. Since 2015, Amazon has reduced packaging per-shipment weight by 43%, representing more than 3 million metric tons of packaging materials avoided.
When packaging is reduced, Amazon can also fit more packages into every van, leading to fewer journeys and bringing them closer to their goal of being net-zero carbon across operations by 2040.
