Smurfit Westrock scales its EnduraGrip paperboard handle across Costco warehouses in North America

The transition from plastic to fiber-based packaging in heavy-duty retail environments has just cleared a significant technical hurdle. Smurfit Westrock has successfully scaled its EnduraGrip paperboard handle across Costco warehouses in the United States and Mexico, replacing the legacy plastic carriers on Kirkland Signature orange juice multipacks.

Replacing plastic in a three-pack beverage format presents a specific set of engineering challenges. The primary issue is uneven weight distribution, compounded by the heavy weight of the liquid, moisture exposure in the cold chain, and unpredictable consumer handling. To address this, Smurfit Westrock engineered a fully recyclable, mono-material handle utilizing a triple-ply folded structure.

Technical specifications of the CarrierKote structure

The structural integrity of the new handle relies on 27-point CarrierKote, a coated natural kraft (CNK) paperboard developed by Smurfit Westrock. The design incorporates engineered fold geometry and staggered apertures specifically calculated to manage the weight imbalance of the three-bottle configuration. This ensures the handle remains secure whether a consumer lifts the pack from the center tab or by an individual bottle.

Beyond load-bearing capabilities, the CarrierKote substrate is optimized for wet strength and refrigeration, critical factors for the orange juice cold chain. The material also provides a printable surface, eliminating the need for additional labels or films to carry branding and sustainability messaging.

Operational integration without capital expenditure

For packaging converters and brands, the most critical aspect of this deployment is its integration into existing production environments. Smurfit Westrock designed the EnduraGrip solution to run on standard filling and application lines, requiring zero new capital investment from the manufacturer. Operationally, the paperboard handles ship flat, which improves cube utilization during transport compared to bulky plastic alternatives, and avoids costly retooling on the packaging floor.

The mono-material design has secured a "Widely Recyclable" pre-qualification from How2Recycle, providing clear recovery guidance for consumers. By successfully scaling this fiber-based solution in a high-volume, demanding retail environment like Costco, Smurfit Westrock demonstrates that paperboard can meet the rigorous performance metrics traditionally dominated by plastic components.