Poly-to-Paper Mailer Transition

Sustainability & Cost Optimization

Client Needs

Move from non-recyclable polybags toward curbside-recyclable paper mailers and reduce package-suite complexity.

The Challenge

Polybags contributed 21,900 MT of waste in 2024 (projected 44,800 MT in 2025 without a paper solution); paper bags increased unit cost.

Our Approach

  • Introduced paper-bag design enabling added product eligibility (moving products from boxes to bags) 
  • Began removing padded mailers in favor of single-ply kraft paper 
  • Rolled out to ~10% of sites

The Impact

  • Saved $18M in 2024 (of a projected $172M by end of 2025: ~$47M material, ~$33M labor, ~$95M transportation).
  • Targeting 20% package-suite complexity reduction.

Let’s Talk Efficiency Gains

Want to reduce production costs, increase throughput, or optimize your packaging line? Let’s connect.

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