Lego has replaced the single use plastic packaging used for their sets with paper bags. In 2024, over 90% of Lego's packaging is paper-based.

Dry moulded paper packaging, produced from multiple layers of paper pressed and bonded together with heat. While the raw materials are more expensive than moulded pulp, the production rate is much faster and energy costs are lower. The raw material prices are decreasing as the paper is becoming available from more mills. The challenge is finding paper webs (rolls) with crosswise grain, to ensure high strength and stable packaging when laminated together with the conventional lengthwise grain stock. These examples were produced on an OMG Thermoforming machine.

Push Tab paper-based blister packaging by Syntegon and Huhtamaki, using FibreForm paper-based (75%) material. It provides an alternative to conventional blister packs made from polyvinyl chloride (PVC) and aluminium foil. The thermoforming technology developed by Syntegon enables the production of trays, pods, blister packs and pouches - many types of packaging previously not possible with paper. FibreForm can be used on its own, or laminated or coated to provide barrier properties and heat-sealing, for example. The coating provided by Huhtamaki provides barrier and sealing properties. With biodegradable plastics it is possible to maintain the compostability of the paper. Image Syntegon.

Thermformed paper-based sweet packaging made with FibreForm by Billerud. Produced with a modified type of kraft pulp, it is more formable than regular paper, and can be shaped into trays, blister packs and pouches. Image Billerud.