Amazon is pushing forward with the replacement of single-use plastics in its shipping packaging. A key role in this is played by so-called stretch film, which is intended to suit automated packaging processes and has been used in Europe for several years already.
The so-called „extensible paper“ can expand by up to five to seven percent without tearing, according to Amazon. This makes it about two to three times more flexible than conventional kraft paper. Thanks to this property, the material can better adapt to products and absorb loads. According to Amazon, the paper has been used in Europe since 2021. Starting in 2025, it will also be rolled out in the North American logistics network.
Paper for automated packaging processes
One challenge in switching from plastic to paper is the processing on automated machines. Plastic can be sealed hot with relatively little effort and tolerates high processing speeds. Paper, however, can tear especially at folding points under stress and requires more precise machine technology. The higher tensile strength of the paper used is intended to reduce these disadvantages.
Amazon has retrofitted existing packaging machines for this purpose. They take the paper from the roll, adjust the packaging size to the respective product, and then perform sealing, cutting, and labeling. Additionally, the company developed water-soluble coatings that allow the paper to be sealed hot, similar to plastic, according to Amazon. The coatings were tested to ensure that they do not impair the recovery of the paper fibers during recycling.
Packaging in the stress test
Before deployment, materials and packaging are tested in two Amazon laboratories. Tests include, among other things, tear resistance and performance in the presence of moisture and mechanical stress. A test procedure developed jointly with the International Safe Transit Association includes 17 case tests and two vibration phases within a 90-minute cycle. This is intended to simulate loads from the fulfillment center to the doorstep.
According to company reports, automated packaging systems in North America avoided the use of 288 million plastic bags in 2025. The share of shipments there with disposable plastic shipping packaging decreased from 65 to 37 percent within a year. Additionally, 11 percent of orders worldwide were delivered in 2025 without additional Amazon packaging.
Source: Amazon
