How to Replace Polystyrene Inserts — PPWR Guide

Are you working to reduce the use of plastics and polystyrene in packaging and comply with PPWR requirements? Great. We’ll show you how to effectively replace polystyrene inserts with a more sustainable material we’ve been developing for several years and share the results of stress tests. You’ll be pleasantly surprised!

What is PPWR and how does it affect packaging in Czech companies?

The Packaging and Packaging Waste Regulation (PPWR) was created to reduce packaging waste, support recycling, and improve packaging sustainability.

PPWR entered into force on 11 February 2025. From that day an 18‑month period began for companies and entrepreneurs to adapt to the new rules. Most of them start to apply from 12 August 2026.

Key PPWR changes for day‑to‑day operations

For Czech companies, PPWR will mean a phased implementation, for example:

• reducing plastic packaging and replacing it with more sustainable alternatives,
• increased requirements for packaging recyclability,
• obligations to use recycled materials in new packaging,
• reducing over‑packaging and greater support for reusable packaging.

Plastic packaging, or polystyrene inserts like the one pictured, will soon be a thing of the past. Many entrepreneurs and companies are not waiting and are already introducing more eco‑friendly solutions.

A sustainable alternative to polystyrene exists

Card and corrugated board are sustainable materials that, with the right know‑how, can replace plastic packaging, polystyrene inserts, and void fills. Corrugated board is manufactured largely from recycled content. It is a naturally eco‑friendly material which, with the right structural design, can even outperform standard polystyrene inserts in strength and protective properties.

In 2022 we began developing a new, improved way of packing and securing products using corrugated board. The main goal was to meet all customer requirements and find a solution that fully replaces synthetic materials commonly used to secure products inside packaging.

“We created the insert thanks to new technical solutions and modern ways of processing corrugated board that are not commonly used on the market. This enables us to produce very complex special constructions that do not lose their strength and are suitable even for packaging heavy items.”
says Palo Lezo, CEO Paketo group s. r. o.

The result is boxes with inserts developed in line with PPWR, easy to assemble and with technical and safety properties at least on a par with the previous polystyrene or plastic inserts.

Two types of modern eco‑friendly inserts

a) Grid‑type insert (PRODUCT FIT – GRID INSERT)

This insert type is suitable for packing and transporting geometrically complex products of both higher and lower weight. This design meets the conditions for safe, stackable, and at the same time design‑led packaging that is eco‑friendly and fully replaces the original polystyrene inserts.

b) Shell‑type insert (PRODUCT FIT – SHELL INSERT)

This is a corrugated board insert where a precise die‑cut follows the product’s contours and forms a protective shell that holds the product firmly in place. In this case, the outer box serves only for closure and visual appeal.

Why is corrugated board better than polystyrene?

When developing both insert types, we carried out many stress tests simulating situations that can occur in everyday operations, handling and transport of goods (drops from various heights and angles, stacking boxes, etc.). We also tested extreme conditions.

Transport safety

The results of safety tests of our corrugated board inserts delighted our customers. In some aspects we even exceeded expectations and the protective performance of their previous packaging solutions.

• With polystyrene inserts, impacts cause cracking, which makes them lose their fixing and cushioning properties. Corrugated board inserts cushioned and protected the product even after deformations caused by repeated drops from height.

• In an extreme drop, inside the polystyrene insert the product deformed under its own weight and was damaged. The corrugated insert, by contrast, supported the product and prevented deformation under its own weight.

• In climatic chamber tests, we first simulated conditions typical for air transport, −50°C with 0% humidity. Conditions then changed to +30°C with 90% humidity, typical for equatorial and coastal areas. Such testing is the most demanding and corresponds to the greatest extreme in sudden changes during transport. Insert materials must withstand these conditions to enable deliveries worldwide. In our test, polystyrene inserts suffered undesirable condensation directly on the product, inside the insert. By contrast, the corrugated board insert absorbed the moisture and, although this compromised the material’s integrity, it retained the necessary protective properties even in the event of a drop.

Cost savings in storage

A major advantage of inserts made of card and corrugated board is their low demand on storage and logistics. This is thanks to the ability to store inserts flat and then assemble them easily. For one of our customers, we achieved up to a tenfold saving of space in storage and transport compared with the original polystyrene insert solution.

Environmental aspects

Thanks to a radical reduction in the space required by inserts, especially during transport, the product’s carbon footprint was dramatically reduced. Another benefit is the high recycled content in corrugated board and the FSC® certification of all material used to produce these protective packs. This ensures the sustainability and renewability of the resources used to make these materials and therefore environmental friendliness. At the same time, we achieved simplified recycling of the pack, which is entirely paper‑based and thus much more suitable for recycling than polystyrene. End customers can also reuse the packaging for various purposes thanks to the quality materials, extending its service life.

Original design

The very construction of a corrugated board pack with an insert is highly original and unconventional, creating a “wow effect” when unboxing. Thanks to our technology, we can further enhance the packaging solution with custom print. This emphasises the aesthetic effect and helps connect the packaging and product more closely with the brand, strengthening brand perception.

Looking for an eco‑friendly and safe alternative to polystyrene and plastic inserts?

Do you want a custom packaging solution that will protect your products and be compliant with PPWR?

Contact us and we’ll help you develop a sustainable packaging solution tailored to your products.