Costco Swaps Plastic Handles for Paper

Costco wanted to replace the plastic “dog bone” handles used on Kirkland Signature orange juice multipacks with a recyclable, paper-based alternative—without sacrificing strength, shopper convenience or cold-chain performance. The 3-pack format made that goal especially complex: uneven weight distribution, moisture exposure, heavy weight and varied handling meant the new handle had to stay secure whether consumers lifted from the center tab or by one of the bottles. 

Smurfit Westrock partnered with Costco, manufacturers, brand managers and automation teams to engineer their EnduraGrip® solution, a fully recyclable, mono-material paperboard handle designed to perform like plastic while supporting circular recovery. The solution uses a triple-ply folded structure made from 27-point CarrierKote® coated natural kraft (CNK), with engineered fold geometry and staggered apertures to manage the 3-pack’s weight imbalance. It was optimized for wet strength, print performance, refrigeration, transport and handling, while running on standard filling and application lines with no capital investment. The team also engaged How2Recycle to secure “widely recyclable” prequalification for clear, credible recycling guidance. 

EnduraGrip® is now scaled across Costco warehouses in the U.S. and Mexico, replacing the legacy plastic handle with a recyclable fiber-based solution that delivers environmental, operational and consumer benefits. The mono-material design is pre-qualified “Widely Recyclable” by How2Recycle, supports clear on-pack sustainability messaging and eliminates the need for extra labels, films or vague green claims. Operationally, it ships flat, improves cube utilization, runs on standard equipment and avoids costly retooling. For shoppers, the paperboard handle offers a familiar, ergonomic carry experience and easier disposal, reinforcing Costco’s sustainability commitment through visible material integrity and third-party validation.