The Irish Spring brand identified an opportunity to position their bodywash at Costco Canada as a twin-pack pump offering, aligning with Costco's sustainability goals.

Traditionally, club retail packs use shrink film, plastic multipack handles and folding boxboard or corrugate cartons.

However, the design team developed an innovative, eco-friendly solution adhering to Costco's "Six Rights of Packaging Sustainability".

Given Canada's higher recycling rates for corrugate packaging (85%) compared to plastics (16%), the team focused on a 100% paper-based solution.

After weeks of design and testing, the team developed the EcoPackLock™, a one-piece E-flute die-cut folder that securely locked the two bottles together.  The design met ASTM requirements and was evaluated across the entire product life cycle.  Following successful internal testing, the EcoPackLock™ was introduced to Costco and finalized for a 3^rd quarter rotation.

A life cycle assessment (LCA) using Compass^® revealed significant environmental benefits compared to traditional plastic multipack handles.  The LCA estimated a 78% reduction in fossil fuel use, a 13% reduction in carbon dioxide emissions, and a 68% reduction in water consumption.  Compared to carton options, the EcoPackLock™ reduces packaging weight by 89%.

With a patent pending, this solution invites other brands to adopt the EcoPackLock™ for their own Costco multipack products.

Entrant Company: Hughes Decorr

Client Company: Colgate-Palmolive Canada Inc.