In a bold step toward circular packaging and improved operational efficiency, Mondi, a global leader in sustainable packaging, has teamed up with ZARELO, a manufacturer of fire starters for fireplaces and barbecues, to launch a recyclable paper-based packaging solution a move that sparks both environmental and operational benefits.
The newly introduced packaging is made from Mondi’s re/cycle FunctionalBarrier Paper 95/5, a high-performance paper that offers moisture resistance, puncture durability, and recyclability in existing European paper streams. This innovative barrier paper now wraps ZARELO’s range of fire starters including coiled wood fibres and compact cubes across three product formats: 32-piece packs, 1 kg, and 2 kg bags.
Paper Power with a Performance Edge
Unlike traditional cardboard or plastic-based solutions, Mondi’s FunctionalBarrier Paper 95/5 is designed to deliver both sustainability and strength. It protects moisture-sensitive fire starters during storage and transport, ensuring they stay dry and ready to use. Made from FSC™ and PEFC-certified sources, the packaging upholds responsible sourcing while enabling full recyclability, where infrastructure permits.
Beyond its protective features, the paper’s superior printability elevates ZARELO’s branding and retail visibility, allowing for a vibrant on-shelf presence in competitive markets.
“This solution combines strong barrier properties with excellent printability, offering both product protection and a premium retail presence all while supporting circularity,” says Francesco Fardella, Business Solution Manager for Functional Paper & Films at Mondi.
From Manual Labor to Automation
The packaging innovation has also delivered operational advantages for ZARELO. Transitioning from rigid cardboard to Mondi’s flexible coated paper allowed the company to automate its filling process. The paper runs seamlessly on ZARELO’s vertical form-fill-seal machines converting, filling, and sealing the packaging without the need for additional adhesives.
“Switching from cardboard to flexible paper-based packaging was a key step in improving efficiency for our filling process,” says Christoph Raithel, Plant Manager at ZARELO. “Our collaboration with Mondi enabled us to scale production and expand our presence beyond Germany into international retail markets, including the UK, Italy, and Poland.”
Lighting the Way to a Circular Future
This packaging development underscores both companies' shared commitment to sustainability and innovation. It also highlights the growing market demand for high performance, paper-based alternatives that support the transition from plastic to paper without compromising product integrity or production efficiency.
As demand for eco-conscious packaging heats up, Mondi and ZARELO's collaboration shows that going green doesn't mean sacrificing performance. Their partnership marks another bright example of how functional design, material science, and strategic collaboration can ignite progress in the world of sustainable packaging.