Introducing paper-based bags to hold LEGO sets seems like a straightforward process.
But the global toy manufacturer has revealed the complexity of the transition as it moves closer to making it happen. paper boxes
LEGO has so far tested 180 different paper varieties – but all of its factories have now started production.
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.”
LEGO’s LinkedIn profile posted about its “great thinking inside and outside the box”.
It added: “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 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.
LEGO’s website explains why it is being done.
“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.”
It 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.”
The paper-based bags are one of a host of moves towards sustainable packaging. Others include:
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