Sonoco Launches Paper-Can Packaging Made Entirely from Recycled Fibre

In a move aligned with the circular economy and net-zero transition in packaging, Sonoco Products Company has launched a rigid paper can in North America that is constructed entirely from recycled fibre, with up to 90% of the material derived from post-consumer sources. The innovation aims to help consumer-goods manufacturers reduce virgin material use, enhance recyclability, and cut greenhouse gas emissions through better material design and end-of-life performance.

Product Details and Recyclability

The new “Paper Can – paper bottom” features a body made from 100% recycled paperboard fibre, including up to 90% post-consumer content. It also replaces the traditional metal or plastic base with a paper bottom, allowing the container to be more easily recovered through existing paper recycling streams.

The can has passed repulpability and recyclability tests conducted at Western Michigan University, confirming its compatibility with North American recycling systems. It has also been prequalified for the How2Recycle “Check Locally” label, helping consumers identify it as recyclable in many areas.

By using recycled fibre and eliminating non-paper components, the design enables brand owners to comply more easily with extended producer responsibility (EPR) and recycled-content mandates that are being introduced across North America and Europe. According to Sonoco’s sustainability reporting, switching to all-paper rigid containers can reduce water, energy, and land use compared with packaging made from virgin fibre or mixed materials.

Commercial Rollout and Applications

The product has already been introduced in Europe, where Twinings used the all-paper container for a powdered drink launch in France in 2024. Following this, Sonoco is now rolling out the packaging in North America, targeting food and beverage, snacks, powdered drinks, tea and coffee, pet food, and other consumer-packaged-goods applications. Brand owners across multiple sectors are in discussions to adopt the packaging as part of their sustainability and compliance strategies.

Implications for Sustainability and Net-Zero Goals

Packaging suppliers and consumer brands are under growing pressure to meet recycled-content targets, ensure recyclability, and contribute to carbon-reduction goals. The launch of an all-paper can address several of these requirements simultaneously. a

• Recycled content and virgin-fibre reduction: By using 100% recycled paperboard, including up to 90% post-consumer fibre, the new container reduces dependence on virgin materials. This supports lower-carbon production because recycled fibre generally requires less energy and water to process than virgin pulp.

• End-of-life recyclability: Many rigid containers combine paper, plastic, and metal, which complicates recycling. By replacing metal or plastic ends with a paper bottom, Sonoco’s design allows the entire package to be processed in the paper recycling stream. This supports a circular economy approach, where recovered fibre can be reintroduced into new packaging products.

• Regulatory compliance and risk mitigation: Governments across North America and Europe are tightening rules on packaging recyclability and recycled content. EPR fees and eco-modulation schemes increasingly reward easily recyclable formats while penalising difficult-to-process materials. A fully paper-based system can help brands reduce regulatory risk and achieve compliance without major supply-chain disruption.

• Carbon and resource efficiency: Replacing composite or metal packaging components with paper can lower weight, reduce transport emissions, and simplify material sourcing. Sonoco has indicated that its all-paper design can achieve lower water and energy use compared with conventional formats, supporting corporate carbon-reduction goals.

Challenges and Considerations

While the innovation is a significant step forward, several challenges remain for industry adoption.

• Infrastructure and sorting capacity: Recycling systems vary widely by region, and while tests show they can perform well under optimal conditions, effective recovery depends on local sorting technologies and municipal collection systems. Continued investment in advanced material-recovery facilities will be necessary for consistent recycling outcomes.

• Product performance and barrier properties: Some food and beverage products require high levels of barrier protection against moisture, oxygen, or light. The paper can include coatings and seals to maintain performance, but brands will need to test suitability for individual products, especially in categories with long shelf-life or freshness requirements.

• Consumer participation: Even well-designed packaging depends on correct disposal behaviour. Labelling and consumer education are essential to ensure that paper-based cans are placed in the appropriate recycling stream and not discarded as waste.

• Cost and scale: Transitioning to new packaging materials can involve upfront costs and supply-chain adjustments. Although Sonoco has designed the can for compatibility with existing filling and shipping systems, scaling up production and sourcing sufficient recycled fibre at stable prices may take time.

Broader Industry Context

The development of a fully recycled-fibre rigid can signals a wider transformation in the packaging sector. Companies are moving beyond lightweighting and incremental improvement toward fundamental redesign of packaging to achieve circularity.

Packaging typically accounts for a significant share of lifecycle emissions in consumer goods. Reducing virgin material use and improving recyclability can therefore make a measurable contribution to corporate net-zero strategies. As EPR schemes, carbon accounting, and consumer expectations tighten, validated circular packaging formats are likely to become key differentiators for brands and suppliers.

Moreover, the innovation reinforces the importance of collaboration between packaging producers, recycling facilities, and policymakers. Trials have shown that paper-based rigid containers can reach recovery rates above 90% when properly sorted, suggesting strong potential if infrastructure and design continue to align.

Conclusion

Sonoco’s 100% recycled-fibre paper can mark a practical and credible advance in sustainable packaging. It demonstrates how product design can align with circular-economy goals by reducing virgin material use, improving recyclability, and supporting net-zero ambitions. For consumer-goods brands, packaging converters, and recyclers, the solution offers a pathway to lower environmental impact and compliance with evolving regulatory frameworks. Continued progress, however, will depend on ensuring recycling infrastructure keeps pace, product performance meets market needs, and cost structures support widespread adoption.

Source: nutraceuticalbusinessreview.com