Mathys AG, now part of Enovis, is redefining packaging for surgical implants with a recyclable paperboard solution that challenges long-standing norms in the medical device sector.
Working with Graphic Packaging, the Swiss manufacturer developed a fully fiber-based system for hip and knee implants that removes non-recyclable polyurethane foam, simplifies the supply chain, and enhances usability in operating rooms.
Rethinking Medical Device Packaging
Until recently, implant packaging at Mathys AG relied on multiple SKU formats and petroleum-based foam inserts. This limited recyclability and added operational complexity. With rising sustainability expectations from hospitals and regulatory bodies, the company initiated a complete redesign to reduce waste and streamline logistics.
A Fiber-Based System
The result is a three-piece, all-paperboard pack featuring a stabilizing insert for the sterile bag, a reinforced carton, and a honeycomb inlay that adapts to different implant shapes and sizes. The inlay cushions the product during transport and eliminates the need for separate packaging for each model.
Reducing SKUs from five to two, the solution is lighter, easier to assemble, and recyclable through standard paper streams. Switching to renewable fiber also cut the package weight by 23%, lowering emissions associated with transport.
Operational and Clinical Benefits
Beyond sustainability, the new design offers practical advantages for healthcare teams. Features such as clear labeling areas, easy-open perforations, and pre-glued components improve usability and speed of access in critical environments. The simplified structure also supports direct-to-site delivery and reduces inventory handling.
International Recognition
The packaging has received widespread industry attention, winning several major awards, including the 2025 WorldStar Award, the AmeriStar Awards, the European Carton Excellence Awards Gold Award in Pharma & Healthcare, the Richard DePaul Award for Creative Design & Converting, and the Swiss Packaging Award.
Judges highlighted the combination of functional design, reduced plastics, ergonomic handling, and its alignment with circular economy principles.
A Model for the Sector
As hospitals, regulators, and device manufacturers accelerate their sustainability commitments, the Mathys AG solution demonstrates that packaging innovation can improve both environmental performance and operational outcomes. The project signals a shift toward circular materials in medical device supply chains—without compromising on product protection or clinical expectations.
The success of this fiber-based solution shows how collaboration, engineering, and design thinking can elevate packaging from a logistical necessity to a strategic differentiator. With growing pressure to phase out plastics in healthcare settings, this paperboard solution offers a clear template for future medical packaging.
Graphic Packaging International is a global provider of fiber-based packaging solutions for food, beverage, healthcare, and consumer products. The company designs and manufactures paperboard packaging systems that emphasize sustainability, operational efficiency, and high-performance product protection. Its portfolio includes folding cartons, specialty containers, and packaging machinery serving customers in more than 30 countries.
Source: Graphic Packaging
