LEGO's Paper-Based Bags: A Sustainability Milestone

LEGO is transitioning to paper-based bags for its sets, a move that aligns with its commitment to sustainable packaging. While the concept may sound straightforward, the global toy manufacturer highlights the complexity of this shift, which involves testing, innovation, and extensive collaboration across its production network.

After evaluating 180 different paper types and formats, LEGO has now begun rolling out paper-based bags across its factories, marking a significant step in its sustainability journey.

Progress on LEGO’s paper-based packaging

Annette Stube, Chief Sustainability Officer at LEGO, describes the aforementioned initiative as part of a broader effort to eliminate single-use plastics.

“I’m excited to share our progress moving to paper-based bags in LEGO sets – taking out single-use packaging," she says. 

"We are not finished yet, but our team of clever and creative colleagues are working hard globally to make this important transition happen.”

According to LEGO, its factories worldwide have started producing the new packaging. Sets in Europe and Asia already include paper-based bags, with plans to expand the rollout to the Americas. These bags are durable, easy to fold and verified recyclable in the European Union, US and Canada.

A post on LEGO’s LinkedIn profile calls the transition “a challenging yet important part of our sustainability journey” and highlights the scale of work involved:

• 180 paper varieties tested before selecting the final option.
• All LEGO factories globally have started production.
• Paper bags are being added to more sets across different regions.
• The new design ensures bags are robust, will not tear during transit and are suitable for all climates.

Overcoming challenges in the paper transition

The shift to paper-based packaging has proven far from simple. LEGO underscores the effort required to meet its high standards for durability and practicality, while also catering to a global market with varying environmental conditions.

“Packing LEGO bricks into paper-based bags might sound simple, but the reality is more complex,” the company explains. “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.”

Paper is particularly sensitive to humidity, which posed an additional challenge in developing a material suitable for use in diverse climates. To ensure functionality, LEGO tested 15 different prototypes, with input from hundreds of children and parents. This testing extended to shape, materials, and graphic designs to enhance the experience of opening the bags.

Interestingly, the paper bags introduced an unintended but welcome benefit: a more engaging unwrapping experience. Unlike transparent plastic bags, the paper-based versions add a sense of surprise and excitement, which children particularly enjoy. The larger bags are also designed to stand upright, making them convenient for storing bricks during the building process.

A broader commitment to sustainability

Paper-based bags represent just one element of LEGO’s broader sustainability strategy.

On its website, LEGO explains its long-term goals for recyclable and responsibly sourced packaging: “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 working hard to make this transition across all our factories.”

LEGO aims for all its packaging to be made from renewable or recycled materials, certified by the Forest Stewardship Council. The organisation also ensures that its packaging protects the contents of each set, preventing lost pieces during transit.

Other steps in LEGO’s sustainable packaging initiatives include:

• LEGO boxes made from responsibly sourced materials.
• Baseplate packaging replaced with paper-based alternatives.
• Phasing out single-use plastic retail bags in stores since 2020.
• Replacing plastic cups in LEGO Pick a Brick with flat-pack paper containers.
• Switching Build a Minifigure packaging from plastic to recyclable cardboard.

As LEGO continues to innovate in sustainable packaging, paper-based bags are setting a precedent for environmentally-conscious design without compromising the quality fans expect.

Reflecting on the progress, LEGO states: “This transition has been a challenging yet important part of our sustainability journey.”

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