Lego Manufacturing Vietnam is setting a new benchmark in environmentally responsible manufacturing. As the Lego Group’s first factory to produce only paper-based pre-pack bags, the new facility symbolizes a major step toward eliminating single-use plastics in its global packaging strategy. Located in Vietnam’s Binh Duong province, the factory is not only expanding Lego’s reach in Asia but also demonstrating what modern, sustainable manufacturing can look like.
Replacing Plastic with Certified Paper
One of the most significant milestones at Lego Manufacturing Vietnam is the transition from plastic to paper-based bags inside Lego sets. These bags—used to organize bricks by building stages—are now being made from paper sourced exclusively from Forest Stewardship Council (FSC) certified forests and FSC-controlled wood. This move is central to Lego’s broader sustainability goal of removing single-use plastics from its packaging.
To develop the new bags, the company tested nearly 180 paper variations for strength, resilience, and climate adaptability. These tests ensured that the paper performs well in diverse weather conditions, from the humidity of Southeast Asia to colder regions in Europe and North America. Feedback from children showed that the new packaging was well received, with the paper bags holding up to the rigors of play and repeated use.
Key Features of Lego Manufacturing Vietnam
- Environmentally Sustainable Packaging: The factory produces paper-based pre-pack bags made from FSC-certified materials, helping to eliminate single-use plastics from Lego products.
- Renewable Energy Infrastructure: Over 12,000 solar panels have been installed at the site, and the factory will operate fully on renewable energy by 2026.
- Energy Storage Innovation: The site includes Vietnam’s first large-scale battery storage system, helping to optimize renewable energy usage across the plant.
- Climate-Resilient Packaging: Extensive testing of different paper types ensures durability in various climates, ensuring that the packaging remains effective for global distribution.
- Local Impact: The factory’s location in the Asia-Pacific region allows for more efficient distribution of products, reducing carbon emissions related to long-distance shipping.
Advanced Renewable Energy Infrastructure
Lego Manufacturing Vietnam is also leading in energy innovation. The site is designed to run entirely on renewable energy by 2026. The plant already features over 12,000 rooftop solar panels, significantly reducing its carbon footprint. But the company isn’t stopping there.
In partnership with the Vietnam-Singapore Industrial Park, Lego is also building a nearby energy center. This facility will include Vietnam’s first large-scale battery storage system of its kind. The battery solution will help balance power supply and demand, especially during periods of peak consumption, ensuring that the plant can maintain operations using clean energy around the clock.
Scaling Sustainable Production in Asia
The opening of Lego Manufacturing Vietnam marks the company’s second production site in Asia and sixth worldwide. The factory will serve as a major distribution hub for the Asia-Pacific region, enabling faster delivery times and reducing transportation-related emissions. This regional manufacturing approach not only improves operational efficiency but also aligns with Lego’s broader climate goals by cutting down long-distance shipping from Europe.
According to company leadership, the new factory represents a commitment to responsible growth. As demand for Lego products rises in Asia, the group is expanding capacity while making a positive environmental impact. The plant’s construction and operation reflect an integrated approach to sustainability—covering packaging, energy, and logistics.
Inspiring Industry Change
Lego Manufacturing Vietnam is more than a factory—it’s a prototype for how large-scale manufacturers can incorporate sustainability into every level of their operations. By investing in renewable energy infrastructure, eliminating single-use plastics, and sourcing materials responsibly, Lego is setting a standard that other global brands may soon follow.
In particular, the use of battery storage solutions and power purchase agreements shows what’s possible when businesses and local governments collaborate to develop forward-thinking energy frameworks. The project could inspire similar models in other developing economies, especially those aiming to attract foreign investment without sacrificing environmental responsibility.
A Future-Focused Facility
As companies across the globe face increasing pressure to reduce their environmental impact, Lego Manufacturing Vietnam provides a roadmap for progress. From eco-friendly packaging to solar power and advanced battery storage, the site brings together innovation, sustainability, and scalability in one location.
For the Lego Group, this new plant is more than a production site—it’s a declaration that sustainable manufacturing is not only achievable but essential for the future of the toy industry. As Lego continues to build a greener global supply chain, its Vietnam factory will likely play a pivotal role in shaping what responsible manufacturing looks like in the years to come.