Breakthrough for beverage makers: fibre screw caps now cost-competitive with fossil plastic

Blue Ocean Closures (BOC), the Swedish innovator in fibre-based packaging, is set to revolutionise the beverage industry by announcing a major commercial milestone: its latest generation of fibre screw caps is now positioned to match or even beat fossil plastic in material cost, while drastically reducing production energy consumption.

This breakthrough means drink makers can now choose a sustainable, circular packaging component that is not only the superior environmental choice but also a commercially competitive solution for their high-volume production needs.

BOC’s new cost position is the result of continuous refinement in its proprietary forming technology, which utilises virgin or recycled carton board feedstock. This material is both widely available and less expensive than the traditional materials used in conventional fibre-forming and fossil-based plastics.

For beverage manufacturers, the production advantages are significant:

• Ultra-fast production: the technology enables production cycles of under two seconds.
• Low energy use: The energy requirement is approximately one-tenth that of conventional plastic moulding.
• This combination of low-cost substrate, high speed, and minimal energy consumption establishes BOC’s fibre closures as a cost-leading, low-carbon alternative for the bottling and packaging of drinks.

The new cost structure accelerates the adoption of fibre closures, which are already gaining traction among forward-thinking brands like The Absolut Group.

BOC’s closures are designed to be recyclable and integrate seamlessly into existing paper recycling systems, directly supporting the accelerating demand for circular packaging solutions driven by global brand commitments and new EU regulations.

Beyond cost and sustainability, these fibre closures offer drink brands a new opportunity for differentiation and consumer appeal:

• Premium look and feel: the caps offer a natural look and tactile feel that consumers prefer.
• Customisable design: customisable geometry allows for high shelf impact, helping brands stand out through both design and sustainability.

Lars Sandberg, CEO of Blue Ocean Closures, summarised the impact: “For the first time, we can say that fibre-based closures can be cost competitive — or even lower in cost — compared to fossil plastics, while using only a fraction of the energy. This is the moment when sustainability and profitability truly align.”