In a bold step toward reducing plastic use in everyday products, Carton Service and Stora Enso have introduced a gable top carton refill made from renewable paperboard for foaming hand soap.
The initiative, launched in 2023, positions fiber-based packaging as a viable alternative to traditional plastic bottles in the personal care segment.
Ohio-based Carton Service, a folding carton manufacturer known for its gable top packaging, led the project and sought the expertise of Stora Enso to source and develop a liquid packaging board that could handle the technical demands of soap products. The result: a packaging solution that breaks new ground for both functionality and sustainability.
“This was an underserved market,” said Scott Garverick, VP of Business Development at Carton Service. “We saw the opportunity to be first to market with a nontraditional product in a gable top carton, replacing fossil-based plastic with renewable materials.”
To bring the concept to life, the team worked closely with NiMCO, a specialist in gable top packaging machinery. Adjustments were needed to accommodate the rigidity of Stora Enso’s Natura board, and multiple trials helped fine-tune barrier properties, sealing performance, and printing quality. The board was ultimately modified with an aluminum barrier to ensure chemical resistance and shelf stability.
During the COVID-19 pandemic, global supply chain disruptions complicated development. Yet, through cross-functional collaboration, Carton Service and Stora Enso overcame challenges from material testing to machine optimization. Waste during production was dramatically reduced—from 20% to just 1%.
Mike Robinette, Director of Business Development at Carton Service, credited Stora Enso’s involvement: “They were a big difference maker. We wouldn’t be where we are today without them.”
Since its debut, the paperboard-based refill has maintained strong sales and proven the market potential for fiber-based packaging in nontraditional segments. Carton Service is now exploring similar applications in areas like motor oil and cooking oil, while Stora Enso is pursuing opportunities in other household products, including laundry detergents and glue.
“This is about rethinking what’s possible,” said Garverick. “We aimed for 100% success—not just 98%. The result is not only a better packaging solution, but a more sustainable one.”
Stora Enso is a leading global provider of renewable products in packaging, biomaterials, wooden construction, and paper. With roots dating back to the 13th century, the company is committed to replacing fossil-based materials with low-carbon, bio-based alternatives. Headquartered in Helsinki, Finland, Stora Enso operates globally and is listed on the Helsinki and Stockholm stock exchanges.
