WorldStar 2026: FiberFlute’s Success in Replacing PE Foam

Nefab’s modern recyclable paper-based packaging for efficient logistics earned two awards at the 2026 WorldStar Packaging Awards in the categories Packaging Materials and Components and Transit. The recognition supports a clear message: replacing PE foam with FiberFlute is not only feasible—it delivers concrete improvements in logistics performance and sustainability.

Rethinking Foam for Electronics Packaging

This project focused on finding a better way to package sensitive electronic devices. Previously, the customer's packaging solution relied on PE foam and corrugated board—effective but bulky, and challenging to recycle. The goal was clear: move to a single-material, paper-based design without sacrificing protection.

We addressed these issues by redesigning the package with FiberFlute, a fully recyclable, paper-based cushioning solution, paired with a corrugated box.

Demonstrated Benefits of the FiberFlute Solution:

• Sustainability: Transitioning to fiber-based materials removes plastic waste and reduces CO2 emissions by 22%, according to GreenCalc's life-cycle assessment. The solution saves 26 tons of CO₂ emissions annually.

• Transport Efficiency: FiberFlute is more volume-efficient than PE foam, which allows for more compact external dimensions. As a result, 280 more packages can fit in each truckload, increasing shipment efficiency and lowering transport cost and CO2.

• Enhanced Protection: Rigorous vibration and drop tests confirmed FiberFlute’s reliable cushioning performance, keeping electronics safe across long distances.

WorldStar 2026 Honors Efficient Sustainability

The WorldStar Awards, hosted by the World Packaging Organisation (WPO), honor only the most impactful solutions in packaging worldwide. Securing awards in two categories underscores that FiberFlute is a valid alternative to PE foam—offering both environmental and operational gains. The case sets a practical example for the industry to follow.

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Fiber Packaging : Nefab's custom fiber packaging solutions offer lightweight protection and sustainability through renewable materials that are easy to recycle anywhere in the world.  

FiberFlute Cushioning: Discover FiberFlute, a paper-based and recyclable alternative to foam. 

GreenCalc: Nefab’s own certified calculator measures and quantifies financial and environmental savings in our solutions