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- Carton Converter: Graphic Packaging International
- Brand Owner: Mathys AG
- Structural Designer: Graphic Packaging International
- Graphic Designer: Graphic Packaging International
- European Carton Excellence Awards 2025
The new packaging concept for Mathys AG’s hip and knee implants replaces the previous polyurethane foam inlay with a fully recyclable, paperboard-only solution – combining medical-grade protection with environmental responsibility.
Designed as a custom three-piece structure, the packaging includes an integrated paperboard honeycomb inlay that adapts precisely to the shape of the implant, ensuring secure stabilisation without the need for additional materials.
The system consists of an easy-open outer box, an inner folding box with a hinged lid, and a paperboard insert that supports the sterile bag, delivering both structural integrity and ease of handling. The honeycomb inlay not only cushions the implant but allows for consistent, foam-free protection across a range of formats.
The redesign reduces packaging Stock Keeping Units from five to two, significantly improving operational efficiency. Developed with full compliance in mind, the new format meets strict medical certification standards while aligning with upcoming sustainability regulations, including the EU’s Packaging and Packaging Waste Regulation.
The design supports both circularity and logistics optimisation, resulting in a future-ready packaging solution that maintains medical certification while prioritising convenience and functionality.
