Mondi launches recyclable  Protective Mailers, appoints innovation director 

UK – Mondi, a global packaging and paper company, has introduced the Protective Mailer, a fully recyclable paper-based solution designed for eCommerce shipments. 

This innovation replaces plastic bubble wrap with open flute paper, which provides equivalent product protection while maintaining compatibility with standard recycling streams. 

Developed in collaboration with major online marketplaces, the mailer addresses the growing demand for eco-friendly alternatives in the sector, which sees billions of packages shipped annually.

The launch coincides with the appointment of Gavin Mounce as eCommerce Application and Innovation Director, effective November 1, 2025. 

Mounce, who joins with extensive background in packaging design from both supplier and retailer perspectives, will oversee the integration of Mondi’s converting capabilities and paper expertise. 

His role focuses on accelerating the development of solutions that meet supply chain demands without compromising environmental standards.

Armand Schoonbrood, COO of Mondi eCommerce, highlighted the strategic fit. He stated that eCommerce packaging must deliver value for both the environment and customers.

Schoonbrood noted Mounce’s retailer insights would enable designs optimized for planetary and human benefits, turning concepts into tested deliveries.

This move builds on Mondi’s established infrastructure for innovation. The company’s ISTA-certified testing laboratory simulates real-world logistics conditions to validate performance. 

In the Czech Republic, the ThinkBox Bupak facility serves as a dedicated space where clients co-create samples, conduct workshops, and align packaging with operational needs.

Schoonbrood emphasized that rigorous testing ensures solutions withstand the full journey from warehouse to doorstep.

The Protective Mailer exemplifies Mondi’s shift toward resource-efficient materials. Weighing less than traditional options, it reduces shipping volumes and carbon emissions during transport. 

Early trials with partners have shown it withstands drops, vibrations, and compression equivalent to plastic liners, all while using 100% paper sourced from managed forests.

Production scalability allows for customization in sizes and branding, fitting diverse eCommerce inventories.

In a related development, recent industry efforts underscore the momentum in sustainable packaging. 

A September 2025 initiative by the Gulf Petrochemicals and Chemicals Association (GPCA) in the Middle East launched a US$5 million fund to support circular economy projects, including recyclable eCommerce wraps. 

This complements Mondi’s advancements by fostering regional adoption of fiber-based alternatives, potentially cutting plastic waste by 20% in high-volume markets over the next three years.

Mondi plans to expand the Protective Mailer line with enhanced moisture resistance features by mid-2026.

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