The challenge
Medicon was looking for a packaging solution for Indivisual contact lens systems that could replace conventional plastic trays without compromising medical requirements. The packaging needed to hold individual lenses securely, remain stable during transport and support efficient handling in professional environments. At the same time, sustainability had to be practical and easy to explain. The goal was not to introduce new disposal complexity, but to move towards a material choice that fits existing recycling and composting routes.
The PaperFoam® solution
PaperFoam® designed a custom-molded tray made from biobased materials, shaped specifically around the Indivisual lens units. The tray keeps each lens in a fixed position and provides shock absorption during transport and storage. Compared to plastic alternatives, the PaperFoam® tray is lighter and easier to stack. At end of life, the material can be recycled with paper or composted, depending on local systems. More details on material behavior are available on our recyclability and compostability page.
Design and handling
The packaging consists of a hinged tray structure that opens cleanly and holds the lenses in an organised layout. This improves clarity and handling speed in clinical and professional settings where efficiency matters. A printed outer sleeve completes the packaging, allowing Indivisual branding to remain visible while the PaperFoam® interior focuses on protection and functionality. Separating branding from the structural component keeps the packaging flexible and scalable.
Impact and results
By switching to PaperFoam®, Medicon reduced the use of fossil-based plastics for this packaging application. The lower material weight also contributes to more efficient transport and reduced emissions across the supply chain. This project shows that biobased materials can meet medical packaging requirements when design, material choice and production are aligned. Similar medical applications can be found in our portfolio.
Medical packaging applications
Medical packaging requires consistency, repeatability and documented material performance. PaperFoam® works closely with partners to ensure packaging designs fit existing workflows and meet regulatory expectations. For teams evaluating alternatives to plastic trays or inserts, a material comparison is often the best first step. Our premium sample kit allows you to assess fit, surface quality and handling before moving into custom tooling. Learn more about our experience in this sector on the medical packaging overview page.
Considering a similar packaging transition?
If your product requires precise positioning, clean presentation and a lower environmental footprint, a molded PaperFoam® solution can be a suitable next step. Our team supports projects from early concept through production and scaling. Contact PaperFoam® to discuss your packaging challenge or explore related developments in our news section.
