Megaflex Schaumstoff switches from plastic to Mondi’s Protector Bag ExpandForm created from kraft paper for its mattress rollpacking; the new packaging is recyclable, requires little adaption to existing packing equipment

Sample article from our Packaging Industry

May 1, 2023 (press release) –

  • Mondi partnered with mattress producer Megaflex Schaumstoff to introduce Protector Bag ExpandForm for mattress rollpacking
  • Created from Mondi kraft paper, the new packaging is made from renewable materials and is easy to dispose of and recycle in existing paper waste streams
  • The paper bag is customisable in size, and requires little adaption to existing packing equipment

Mondi, a global leader in sustainable packaging and paper, has created Protector Bag ExpandForm, a paperbag solution with an expandable feature to safely rollpack mattresses.

 Protector Bag ExpandForm replaces the current  plastic packaging with a flexible and recyclable alternative. The solution is also customisable and can expand to different sizes while holding the mattress securely. The packaging is made with Mondi’s kraft paper, which is responsibly sourced and renewable, and can be recycled contributing to a circular economy. The paper bag is puncture resistant and suitable for printing, meaning brands can customise their deliveries with a high-quality finish. Unlike plastic, the paper layers are also breathable and can emit gas that can evaporate easily with this new packaging.

 Megaflex Schaumstoff, a family-owned manufacturer for flexible foams and mattresses and sleeping products, is the first company to protect its products with this new packaging. Megaflex collaborated closely with Mondi and machine producer FillMatic to ensure a smooth switch from its current plastic rollpacking equipment.

The collaboration meant that the new solution was quickly up and running and with only a few adaptations to the packaging machinery. Looking forward, Megaflex plans to substitute the full range of plastic rollpacking with paper by the end of 2023 using Mondi’s Protector Bag ExpandForm.

Plastic rollpack wrapping can expand up to 200% in transit, taking up space and potentially deforming outer cardboard packaging. A benefit of Protector Bag ExpandForm meanwhile is that it is dimensionally stable – saving on shipping and storage costs.

 "Consumers are actively seeking packaging that is responsibly sourced and easy to recycle. This new solution ticks both boxes: it is easier to open and to dispose compared to large rolls of plastic and avoidable packaging used previously. Protector Bag ExpandForm needs no secondary packaging to protect the product and will be stable throughout the whole delivery journey. We are proud to be the first ones to introduce this innovative solution to the market." --Fabio Barbieri, Sales Director Paper Bags, Mondi

Karsten Löhr, Managing Director, Megaflex Schaumstoff says: “The Protector Bag ExpandForm is a perfect fit for our mattresses and the plastic saving we estimate is significant - over 18 tonnes every year! The paper packaging is appreciated by our customers, and a big step forward in our sustainability journey, and thanks to our good partnership with Mondi we can use more sustainable packaging, that positively contributes to our sustainability commitments.”

Mondi will be showcasing the Protector Bag ExpandForm and other innovative solutions tailored to the mattress, bedding and upholstery industry at interzum in Cologne Germany, from 09 to 12 May 2023 (Hall 10.1, booth G060).

Judith Wronn, Head of Communication
Flexible Packaging
Tel: +49 151 17714692

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