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Mondi has developed a banana box packaging solution claimed to be as strong as a traditional box, but up to 10% lighter and made with around 40% recycled fibre.

The solution was developed through a collaboration between Mondi, Ecuadorian banana exporter Incarpalm, trading partner Europcell, and a European importer.

Mondi’s technical team for containerboard aimed to discover whether the standard banana box could be made lighter and more sustainable without compromising on strength.

Through the collaboration, the teams redesigned the structure and paper composition of the traditional banana box, testing multiple scenarios to balance durability, weight and humidity resistance.

The new concept combines Mondi’s ProVantage SmartKraft Brown solution, known for its high strength and protective qualities, with its ProVantage Frescoflute, a semi-chemical fluting that enhances firmness in lightweight packaging boxes.

To validate performance under real-world conditions, a full-scale production trial took place in Ecuador in summer 2024.

Bananas packed in the new boxes were shipped to Europe over a 33-day journey, with sensors monitoring humidity and temperature. According to Mondi, despite extreme humidity levels of up to 100%, the boxes maintained their integrity throughout transit.

Marek Motylewski, technical service expert for containerboard products at Mondi, said: “Seeing the new box perform under such tough conditions was incredibly rewarding. It started as a question on a customer visit and turned into a solution that delivers measurable benefits for the entire supply chain.”

Mondi confirmed that the innovation has already sparked interest from other fruit exporters and retailers. It expects demand to rise amid upcoming regulations, including a 2026 EU ban on plastic wrap inside banana boxes.

“This project shows what’s possible when we combine technical expertise with open collaboration,” said Gijs Huisman, sales director at Mondi Containerboard. “It’s a great example of co-creation that delivers tangible results in strength, sustainability and supply chain efficiency.”