A Packaging Transformation

A can carrier is a secondary packaging solution that unitizes multiple beverage cans (commonly 4- or 6-packs) into a single, manageable multipack. The sector has evolved from low-cost plastic ring carriers introduced in the 1960s to contemporary paperboard alternatives driven by sustainability and regulatory pressures.

Definition and scope

A can carrier is a secondary packaging device designed to hold and transport multiple aluminum beverage cans as a single unit. It provides handling convenience for consumers, protection during transport and retail display, and a way to present brand graphics and labeling. Typical formats include flexible rings, molded plastics, and paperboard sleeves or trays. While the functional goal — unitization and protection — remains constant, materials and design priorities have shifted as a result of environmental concerns, manufacturing advances, and logistics requirements.

Historical overview: the plastic era

Plastic ring carriers were introduced in the 1960s and gained rapid adoption through the 1970s. These lightweight, inexpensive carriers were made from injection-molded polyethylene or polypropylene and offered strong holding power with minimal material use. For beverage producers they were attractive because of low unit cost, ease of automated application at filling lines, and shelf-ready presentation. Plastic rings required little storage space and added negligible weight to shipments, which helped reduce transportation costs. For several decades plastic rings were the dominant multipack solution in many markets.

Drivers of change: environmental impact and regulation

Awareness of plastic pollution, particularly marine litter and wildlife entanglement, catalyzed scrutiny of plastic ring carriers. Environmental groups highlighted the role of discarded rings in harming seabirds, turtles, and other marine life. As a result, regulators in several jurisdictions moved to curtail or ban certain single-use plastic carriers, and many beverage brands committed to eliminating problematic plastics from their packaging portfolios. These changes created a clear impetus for alternative materials that deliver comparable functionality with lower environmental risk.

Resurgence of paperboard: materials and coatings

Paperboard returned as a mainstream can carrier material, but modern solutions are far more advanced than the simple paper collars of the past. Current paperboard carriers are engineered for moisture resistance, structural integrity, and efficient machine application. Typical base materials include virgin or recycled paperboard grades selected for stiffness and tensile strength. Protective coatings and barriers — such as water-based lacquers, polyethylene or compostable polymer coatings, and clay or mineral-based coatings — are used selectively to improve wet strength and prevent softening in cold or wet retail environments. Some manufacturers employ corrugated or multi-ply constructions to add rigidity while still minimizing material weight.

Design and manufacturing considerations

Designers of paperboard can carriers must balance multiple factors: hold strength to prevent slippage, ease of application and dispensing at filling lines, stackability for pallet and shelf storage, graphic real estate for branding, and manufacturability at high speeds. Die-cutting, folding, and gluing operations must be optimized to meet the cycle speeds of beverage filling lines. Many paperboard carriers are designed to be fully machine-applicable using existing canning line equipment, reducing capital changes for beverage producers transitioning away from plastic rings.

Performance in logistics and retail

From a logistics perspective, paperboard carriers can change palletization patterns and storage density due to slightly different geometries and compressive behavior. However, contemporary designs aim to match or improve on the protective and stacking characteristics of plastic rings. In retail, paperboard offers superior branding opportunities because it provides a larger printable surface, and it can improve consumer perception by signaling sustainability. Paperboard carriers can also simplify in-store recycling streams where consumers separate paper from cans.

Environmental lifecycle and end-of-life

One of the strongest arguments for paperboard carriers is their better performance in circular systems when sourced and disposed of responsibly. Paperboard produced from recycled content and certified sustainable forests reduces cradle-to-gate impacts. End-of-life pathways include recycling through fiber collection streams and, in some cases, composting depending on coatings used. Life-cycle assessments demonstrate that paperboard carriers usually have lower marine pollution risk and can offer favorable greenhouse gas and resource-use profiles compared with certain plastics, although outcomes depend on sourcing, coatings, and local waste infrastructure.

Examples and industry responses

Several major beverage companies have publicly switched from plastic rings to paperboard or other biodegradable carriers in response to regulation and consumer expectations. In regions that restricted single-use plastics, brands deployed paperboard sleeves, wrap-around carriers, and sleeved trays to meet both functionality and compliance. Some manufacturers also explored hybrid systems that combine minimal plastic with recyclable paper elements during the transition period.

Best practices for implementation

• Evaluate material selection by life-cycle impact, recyclability, and compatibility with local waste systems.
• Design for automation: ensure carriers can be applied at target line speeds to avoid bottlenecks.
• Test carriers under real-world cold-chain, condensation, and stacking conditions to validate hold strength and moisture resistance.
• Prioritize recycled fibers and certified sourcing to improve sustainability credentials.
• Consider end-of-life labeling that guides consumers to appropriate disposal routes.

Common pitfalls and mistakes

Common mistakes include selecting a paperboard grade insufficiently resistant to condensation during refrigerated display, underestimating the need for retooling or line modifications, and neglecting to validate consumer handling scenarios that might induce slippage. Another frequent error is over-specifying coatings that complicate recycling or composting; balance is needed between performance and end-of-life compatibility.

Outlook

Can carrier technology will continue to evolve with innovations in fiber chemistry, compostable coatings, and manufacturing processes that reduce material use while maintaining strength. Regulatory pressure and consumer demand for circular, low-impact packaging will likely drive broader adoption of paper-based and other biodegradable carriers. Meanwhile, supply chain actors — from packaging suppliers to beverage producers and retailers — must collaborate to ensure transitions remain cost-effective and operationally seamless.