A new banana box design developed through collaboration between packaging specialists and international fruit exporters is targeting improved sustainability and reduced shipping weight without compromising strength.
The project began when technical experts from Mondi Containerboard explored whether the standard banana box, used worldwide in fruit logistics, could be made lighter and more resource-efficient while maintaining its durability. The initiative brought together Mondi's technical team in Poland, trading partner Europcell, Ecuadorian exporter Incarpalm, and a European importer to test and refine the design over several months.
Banana boxes are a key component of international fruit transport, often enduring long journeys in humid conditions. The team tested various combinations of paper materials, simulating pressure, moisture, and time to determine the best mix of strength and weight reduction.
© Mondi Group
The resulting design combines ProVantage SmartKraft Brown, a high-strength containerboard, with ProVantage Frescoflute, a semi-chemical fluting that improves stiffness in lightweight packaging. The new composition uses approximately 40% recycled fibre and is up to 10% lighter than traditional boxes. Reduced weight lowers transport emissions while preserving fruit protection during transit.
A full-scale production trial was conducted in Ecuador in mid-2024. Bananas were packed into the new boxes and shipped to Europe in two containers equipped with humidity and temperature sensors. Conditions during the 33-day journey reached humidity levels of 96–100%, testing the structural performance of the boxes under real-world export conditions.
According to Jorge Romero, Operations Manager at Incarpalm, the packaging withstood the test. "The reliability of the box is everything. Seeing the new box composition perform under the toughest conditions proves that innovation and practicality can go hand in hand," he said.
The successful trial has drawn interest from other exporters and retailers as the fruit industry moves toward more sustainable packaging solutions. New European regulations set to take effect in 2026 will ban the use of plastic liners inside banana boxes, increasing demand for fibre-based alternatives that can withstand long-distance transport.
Gijs Huisman, Sales Director at Mondi Containerboard, said the collaboration demonstrated a practical approach to improving packaging design through open testing and cross-sector cooperation. "It's about listening, co-creating, and delivering something that works for the entire value chain," he said.
The partners plan to continue refining the design and exploring its potential for wider use across fruit export operations.
© Mondi GroupFor more information:
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