Mondi has partnered with ZARELO to introduce a recyclable paper-based packaging solution for fire starters, combining barrier protection, automation compatibility, and enhanced shelf appeal. The new packaging uses Mondi’s re/cycle FunctionalBarrier Paper 95/5, a paper-based barrier solution designed to protect moisture-sensitive products while maintaining recyclability in established European paper streams.
ZARELO, a manufacturer of coiled wood fibres and compact fire-starting cubes for fireplaces and barbecues, has adopted the new packaging across three retail formats: 32-piece packs, 1 kg, and 2 kg bags. The transition from traditional cardboard to Mondi’s flexible, coated paper packaging allows for puncture resistance, moisture protection, and high-quality printing—key for durability in logistics and branding at the point of sale.
“Fire starters require packaging that keeps them dry and intact while ensuring ease of handling and storage,” said Francesco Fardella, Business Solution Manager for Functional Paper & Films at Mondi. “This solution combines strong barrier properties with excellent printability, offering both product protection and a premium retail presence—all while supporting circularity.”
The switch also marks a major production milestone for ZARELO, enabling the company to move from manual filling to a fully automated vertical packaging line. The re/cycle FunctionalBarrier Paper 95/5 runs seamlessly through converting, filling, and sealing operations without requiring additional adhesives or materials.
“Switching from cardboard to flexible paper-based packaging was a key step in improving efficiency for our filling process,” said 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.”
Mondi’s coated paper is produced entirely in-house and is certified under both FSC™ and PEFC schemes. As part of the company’s re/cycle portfolio, the barrier paper is designed for sustainability-driven applications requiring strength, moisture resistance, and a fully paper-based construction.
The development underscores a broader shift in the consumer goods sector, where functional paper materials are increasingly replacing plastic or rigid substrates—especially for dry or semi-dry goods. The collaboration also illustrates how material innovation and packaging line integration can drive both environmental and operational performance.
