Can it be done?
To assess the feasibility of the new concept, Carton Service collaborated with NiMCO, a leading manufacturer of gable-top packaging machinery. “We specialize in developing unusual things,” said Scott Garverick, VP of Business Development at Carton Service.
“We saw this project as an opportunity to open up a new market niche—a nontraditional product in a gable top carton using renewable material to replace fossil-based plastic. There are materials out there that can get the job done. We saw this as an underserved market and welcomed the chance to be first to do it.”
The project took shape during the Covid-19 pandemic, when supply chain disruptions added complexity to the process. Carton Service engaged us for our technical and innovation expertise in fiber-based packaging materials.
“The Stora Enso team were key to opening the door for this project, especially during the Covid pandemic and associated supply chain concerns,” said Mike Robinette, Director of Business Development at Carton Service.
“Stora Enso enabled material supply and testing through several iterations of the board and brought significant expertise and resources to help us understand key issues. They were a big difference maker, and we wouldn’t be where we are today without them,” he added.
The process: Trials and experimentation
This project involved multiple trials using different versions of Stora Enso’s Natura liquid packaging board. The team needed material that could support the chemical content of the soap, retain the shelf life of the product, and meet design and packaging specifications. Several critical challenges had to be addressed:
1. Barrier performance. To ensure chemical compatibility and shelf-life performance, the team needed an aluminum barrier that would protect the board from the foaming hand soap's ingredients. Following the launch, the team transitioned to a lighter-weight version of the board, which became the standard in 2024.
2. Machine optimization. The rigidity of the board required adjustments to NiMCO’s machinery to maintain carton integrity and sealing performance. The team succeeded in reducing the waste factor from 20 percent to approximately 1 percent.
3. Printing and testing. The packaging featured complex four-color printing and two coatings, matte and gloss, requiring new processes and protocols. Testing methods also had to be adapted to reflect the needs of renewable fiber materials vs. plastic, which required a willingness to change thinking about traditional testing to achieve the same quality standards.
4. Packaging and distribution. The team needed to achieve efficiency on packaging lines and ensure the product could withstand transportation and distribution.
Throughout the process, teamwork across the value chain was key to success, overcoming not only technical but also logistical challenges exacerbated by the global pandemic.
Garverick explained: “We had to look at these challenges from the perspective of the carton on the machine and find that gentle spot where everything works. The team got smarter. We didn’t want to be 98 percent right -- we were aiming to be 100 percent right. This not only resulted in a more effective packaging solution, but also a more sustainable one.”
Opening new doors
This product launched in January 2023 and continues to generate strong sales. The project is opening new opportunities for both companies, and Stora Enso is exploring similar applications for laundry, dish, and hand soaps, glues, and tubes.
Carton Service is expanding into new areas such as motor oil, cooking oil, and other liquid products. “Gable top cartons are not just for milk anymore,” said Robinette. “With the success of this project, Carton Service is ahead of the curve in finding alternative uses for liquid packaging board.”
This project demonstrates the value of close collaboration and innovative thinking in driving breakthrough solutions.
“When you understand the market you want to attack, and align with the proper people, doors keep opening,” summarized Garverick. “This project demonstrates that brand owners can successfully transition in our continued drive towards packaging with increased renewable content and reduced plastic use, which will lead to more innovative solutions in the future.”
