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Mono material corrugated cardboard packaging with cut out

For efficient handling and a sustainable future

From clothing and shoes to electrical goods and books to heavy fitness equipment: More and more consumers are ordering various products online. In doing so, they are increasingly attaching importance to environmentally friendly packaging and sustainable shipping. To meet these growing sustainability demands, packaging manufacturers like us are constantly working on new innovative solutions. One motto here is: use less to no plastic, and instead process more paper-based raw materials. Product packaging made of one basic material, such as corrugated or solid board, so-called mono-material, can also be recycled better than packaging made of several materials.

Mono-material packaging - natural and solid

We have recently developed such a mono-material packaging for a Smart Indoor Cycling Trainer. The sports equipment, to which a bicycle is attached for home training, is characterized by a high weight and has a country-specific power supply unit. The single-material packaging we designed for it is made exclusively of corrugated cardboard on both the outside and inside, so it is completely natural and robust at the same time. We have completely dispensed with plastic and Styrofoam for padding. Special "cardboard pads" ensure the safety of the sports equipment during storage and transport.

Cut-out for subsequent filling of the packaging

The highlight of the mono-material packaging is the integrated cut-out for the country-specific power supply unit. The latter can be easily added to the already assembled packaging at a later date: The power supply unit can be added through a flap in both the product packaging and the transport packaging without having to open the package. The flaps are then securely closed by means of adhesion. This saves storage space, reduces overcapacity and thus tied-up material.

The packaging is also stackable and adapted to global delivery routes. This makes transport more efficient and reduces the ecological footprint. A tear strip, which runs horizontally along all four sides, is used for easy opening of the packaging and uncomplicated removal of the product.

The advantages of single-material packaging like this are obvious: Since it is made purely from renewable raw materials, it is eminently recyclable and therefore very gentle on the environment. In addition, the sturdy corrugated board meets all the requirements of product and transport packaging by getting the heavy indoor trainer from A to B well protected and enabling safe and efficient processes during shipping and loading.

We will be happy to advise you.


My name is Jochen Drösel. My team and I are the people who make things happen at Schumacher Packaging. No matter how special your requirements are: We realize individual solutions, perfectly tailored to your needs. We look forward to hearing from you!