Zipform Packaging Paper Bottle

Zipform Packaging is proud to be innovators of a world first paper bottle made from over 95 percent wood-based fibre, no plastic liner and featuring more than 50 percent post-consumer recycled content.

Our fibre bottle is the first available on the market to feature more than 95% wood-based fibre, zero plastic lining and over 50% recycled paper.

With testing continuing of the next generation of materials, the fibre content is expected to reach beyond 97 percent.

A sustainable innovation over a decade in the making

Our revolutionary paper bottle is the result of years of innovation, driven by David Kilpatrick, Director of Innovation, R&D, Quality and Technical at Zipform Packaging, supported by CEO John Bigley and our Board of Directors.

With an initial focus on round and alternative shaped packaging for food; innovations within the moulded fibre category ultimately led to the development of our threaded paper bottle combined with our linear formed fibre technology.

After years of extensive development and testing, the Zipform Packaging paper bottle is now a viable and scalable alternative to plastic bottles – ready to transform the bottling industry.

It is recyclable and contains over 50% post-consumer recycled content, delivering both environmental benefits and endless design possibilities.

Technical Specifications

Two breakthrough technologies have been used to develop Zipform Packaging’s paper bottle - Linear Form Fibre (LFF) Composite packs for the body, and we have utilised Dry Moulded Fibre (DMF) technology for the neck connector. This enables the fitting and functionality of conventional twist on and off caps.

The process developed by Zipform Packaging creates a barrier that avoids the need for a plastic liner, unlike most other manufacturers of paper bottles. The internal barrier layer for the bottle body is applied through technology similar to a print process – creating a very thin barrier coating, ensuring the bottle retains liquid whilst preventing moisture and oxygen ingress - and maintaining an impressive 95% plus fibre composition. The neck connector will have barrier coatings introduced in a separate process.

How recyclable is the bottle?

With more than 95% fibre content, 50% post-consumer recycled content and proven pulpability, the Zipform Packaging paper bottle would be widely recyclable around the world. The bottle is currently undergoing the standards test method in Australia and is expected to undergo European CEPI recyclability testing in future.

How effective is the internal barrier?

Testing is ongoing for the barrier properties and will be shared with customers once established.  Given we are using established industry standard materials we do not anticipate any major challenges.

What kind of food, beverage or other products are suited to the paper bottle?

All non-carbonated beverages such as dairy, wine and juice, and all nutraceuticals which may currently be in plastic or glass bottles.

How scalable is the paper bottle?

Zipform Packaging’s modular technology allows for rapid bottle size (height) adjustments using a single toolset, enabling the production of multiple bottle sizes without the need for costly retooling. This significantly reduces costs and complexity for customers, facilitating smooth transitions from plastic to paper bottles, adding to the scalability of this solution. With expected production speeds exceeding 300 bottles per minute, our system far surpasses competing paper bottle technologies, which run at much lower speeds.

What consumer products are best suited to the bottle?

With Zipform Packaging’s processes allowing customers the ability to adjust bottle height, we recommend a number of product uses including non-carbonated beverages, dairy and nutraceuticals.

When will the bottle be available in market?

With barrier performance trials under way, it is expected that the paper bottle will be available for brands to take to market in 2027.

What if I want to learn more?

If you are a brand owner and are interested in discussing more about the commercials of the paper bottle, please contact John Bigley, CEO or David Kilpatrick, Director of Innovation, R&D, Quality and Technical at Zipform Packaging.

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Get in touch

If you would like to know more about Zipform Packaging’s paper bottle, email us at info@zipformpackaging.com.au.