Mathys AG Medical Hip and Knee Implant Packaging: Setting a New Standard in Sustainable Medical Device Packaging

Mathys AG Medical Hip and Knee Implant Packaging: Setting a New Standard in Sustainable Medical Device Packaging

In the world of orthopaedic medical devices, packaging innovation is often overlooked. Yet, for Mathys AG (now part of Enovis), the challenge of creating a more circular, more functional, and more convenient packaging solution for hip and knee implants became a catalyst for industry-leading change.

Rethinking Medical Packaging

Mathys AG’s previous packaging relied on non-recyclable polyurethane foam inserts and required multiple SKUs to accommodate different implant sizes. This approach did not support Mathy AG’s sustainability goals and was also operationally complex, prompting the need for a complete redesign.

Paperboard Innovation

Working closely with healthcare professionals and packaging experts, Mathys AG and Graphic Packaging developed a new three-piece packaging system made entirely from paperboard. The design includes:

• A stabilizing insert for the sterile bag
• An outer carton with easy-open perforation
• An inner folding box with a hinged lid
• A honeycomb inlay that adapts to the implant’s shape

This innovative honeycomb inlay cushions implants of varying shapes and sizes, eliminating the need for unique versions for each implant and reducing SKUs from five to two. The result is a fully recyclable package that maintains medical-grade protection and usability.

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A More Circular Solution

The new packaging is a great example of circular design. By replacing petroleum-based foam with paperboard made from renewable wood fiber, we achieved a 23% reduction in weight, lowering transport emissions and material usage. The single-material construction allows the entire package to be recycled through standard paper streams, with no material separation required.  

• Made from renewable raw materials
• Recyclable in household waste streams
• 23% weight reduction
• Reduced emissions from transport

A More Functional Solution

The new packaging delivers operational benefits, including:

• Direct-to-site delivery eliminates unnecessary logistics and handling
• Pre-glued cartons streamline assembly
• Fewer SKUs simplify inventory and reduce storage needs

A More Convenient Solution

The new packaging delivers enhanced convenience to healthcare professionals:

• Offers a large area for clear labelling and important information
• Easy-open features for quick access in high-pressure environments
• Secure containment and cushioning for delicate implants

Award-Winning Recognition

Mathys AG’s updated packaging has garnered international acclaim, winning several of the packaging industry’s most prestigious awards:

WorldStar Award 2025

Hosted by the World Packaging Organisation, these awards honor top achievers in the packaging industry, as entrants must first win a recognized national award to qualify for entry. Applauded for its functional, future-proof, and reduced-plastic solution, the award highlights the packaging’s ergonomic design, recyclability, and operational efficiency.

“A bespoke solution developed closely with the customer to fit their needs and processes, this unique paperboard container provides a functional, future-proof, and reduced-plastic packaging solution for knee and hip implants.”

Paperboard Packaging Competition – Richard DePaul Award for Creative Design & Converting

Hosted by the Paperboard Packaging Council, this competition has recognized innovation in paperboard packaging for more than eight decades. This year’s judging criteria emphasized shelf appeal, user experience, functionality, and technical precision, evaluating paperboard packaging as both an art and a science. 

“The Mathys AG hip and knee implant packaging showcases the kind of inventive craftsmanship this award was created to honor. It’s a practical triumph of creative converting.”

AmeriStar Awards 2025

Hosted by the Institute of Packaging Professionals  (IOPP), the AmeriStar Awards celebrate the very best in design innovation from around the globe, inviting packaging teams to put their creativity in the spotlight.  The packaging won in the Drug and Pharmaceutical Packaging category.

European Carton Excellence Awards 2025

The European Carton Excellence Awards, a scheme hosted by Pro Carton and the European Carton Makers Association (ECMA), highlights the most innovative paperboard packaging designs in Europe, spanning categories from food and beverage to pharmaceuticals and cosmetics. The Mathys AG pack received aGold Award in the Pharma & Healthcare category.

“Each year, the winning entries demonstrate how remarkable our sector’s innovation really is. They show packaging that protects products brilliantly, engages consumers emotionally, and reflects brands responsibly. Above all, they affirm paperboard’s unique advantage as a truly circular, renewable material that is the leading way in sustainable packaging.” 

Swiss Packaging Award 2024

The Swiss Packaging Awards are presented by an expert, neutral, and broad-based jury composed of various representatives from the packaging industry, as well as neutral and independent experts.

Looking to the Future

The Mathys AG pack’s success demonstrates how sustainability and operational excellence can go hand in hand. Its design not only meets the rigorous demands of surgical teams but also promotes circularity in medical packaging. As regulatory pressures and environmental expectations rise, solutions like this will become the gold standard for the healthcare sector.

Mathys AG’s journey from challenge to award-winning innovation is a testament to the power of collaboration, creativity, and a relentless focus on sustainability. The new hip and knee implant packaging is more than just a carton — it’s a blueprint for the future of medical device packaging.