LEGO passes halfway mark in move to paper packaging

The LEGO Group has passed a major point in its plan to move towards more sustainable packaging, with more than half of its brick-packing lines now using paper-based solutions instead of single-use plastic bags. According to the company, 56% of these lines have completed the switch to paper packaging made from certified sources and designed to be technically recyclable.

The shift forms part of LEGO’s wider packaging strategy, with the business reporting that 93% of its packaging by weight already consists of paper, cardboard or other fibre-based materials. Recent research commissioned by the company suggested that recycling is an important issue for younger consumers, with 81% of children surveyed saying they care about recycling and 80% expressing an interest in reducing waste.

The introduction of paper-based brick bags is now largely in place at LEGO’s manufacturing sites in China and Vietnam. Remaining factories in the Czech Republic and Hungary are expected to complete the transition by 2026, followed by the Mexico facility in 2027.

VP, R&D packing and packaging, Jesper Toubøl, explains: We are on an ongoing continuous improvement journey. Once the roll out 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.

As the rollout continues, the LEGO Group has indicated that it will explore ways to improve the speed and efficiency of the new paper-packing lines, with the aim of eventually exceeding the throughput of the plastic-based systems they replace.