As part of a move towards sustainable packaging, the LEGO Group recently announced that more than half of its packing lines have switched from single-use plastic bags to paper-based alternatives.
Currently, 56% of its lines have transitioned to the eco-friendly format, a shift that began in 2022. The company says customers may see paper bags at different times, as each factory is at its own stage of transition.
The rollout affects five factories and has been implemented in China and Vietnam. Remaining facilities in the Czech Republic and Hungary are scheduled for 2026, with Mexico planned for 2027.
Engineering paper-based bags
LEGO engineers and designers tested over 180 paper types and formats to create bags that meet both quality standards and maintain manufacturing processes in various climates.
The bags also needed to remain durable for the building experience, which includes numbered pre-pack bags used to organize bricks in sequence.
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“More than 350 LEGO colleagues came together to solve this important challenge, and what they have achieved is incredible. It has not been easy to balance the importance of the building experience, the quality of the product and the engineering and production challenges with the urgent need to be more sustainable,” said Tim Brooks, VP of Environmental Responsibility at the LEGO Group, in a 2023 statement.
Paper-based bags from recycled materials
The paper-based bags are made from materials sourced from the Forest Stewardship Council certified forests, recycled materials, and other controlled sources.
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The company says that 93% of its packaging by weight consists of paper, cardboard, or other paper-based materials, making most of its packaging recyclable.
Phase one rollout and future packing line output
LEGO representatives said this is phase one of its sustainable packaging rollout. The company plans to increase the output of paper-based packing lines to match or exceed the plastic lines they replace.
“We are on an ongoing continuous improvement journey,” said Jesper Toubøl, LEGO Group vice president, R&D, packing and packaging, in a statement. “Once the rollout of bags is complete, we’ll explore ways to enhance and continue to make the bags, and the building experience they offer children and families, ever better.”
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