Inside the innovation that turned a two-part box into a one-piece winner
Packaging simplification is a growing mandate—from CPGs looking to reduce costs to brands aiming for more sustainable, mono-material formats. That’s why our visit to the mill that helped us eliminate inner liners from a multi-layer cartonboard structure was so significant.
Through fiber engineering and advanced barrier control, this mill developed a dual-function paperboard that replaced the polyethylene inner liner without sacrificing shelf stability, product safety, or visual appeal.
The Engineering Challenge
Our client, a natural foods brand, needed a moisture-resistant folding carton for dry mix products. The original design used:
Clay-coated SBS outer board
Poly-laminated inner liner for moisture barrier
Separate gluing and lamination steps
The mill’s solution was to develop a single-ply, surface-treated SBS board with enhanced Cobb resistance, eliminating the need for a separate liner.
What the New Format Achieved
20% reduction in material cost
One less lamination step
Improved recyclability due to mono-material structure
Faster line speeds during folding/gluing
This approach has applications far beyond dry foods, extending to:
Personal care cartons
Secondary pharma packaging
Cereal and snack boxes
What to Ask About Linerless Designs
Can your board match the barrier profile of my existing liner?
Are moisture, MVTR, and oxygen barriers integrated or laminated?
What print methods are supported on the new surface?
Is the board certified for food or pharma contact?
One Board, No Liners, Zero Compromises
This project proved that inner liner elimination isn’t about cutting corners—it’s about advancing materials. With the right mill partner, it’s possible to simplify structures and enhance performance.
