PKN EXCLUSIVE: In a groundbreaking development, Australian-based Zipform Packaging has launched a paper bottle made from over 95 per cent wood-based fibre, containing no plastic liner, and incorporating more than 50 per cent post-consumer recycled content.
For decades, the packaging industry has been on a quest to develop a truly sustainable alternative to plastic bottles – one that is functional, scalable, and recyclable. While many have tried, few have successfully overcome the technical and commercial challenges involved.
What sets Zipform’s bottle apart from other fibre-based alternatives is its scalable, fast, and economical manufacturing process – a crucial factor for widespread adoption. I spoke with John Bigley, CEO, and David Kilpatrick, R&D, Quality & Innovation director, to uncover the story behind this innovation, the challenges they’ve overcome, and what it means for the future of packaging.
From inspiration to concept
The idea for Zipform’s paper bottle was was always in mind for David Kilpatrick since founding the company back in 2010. Already deeply immersed in fibre-based packaging technology, Kilpatrick began considering how Zipform’s linear forming process for fibre could be adapted to create a viable, scalable alternative to plastic bottles.
“We’ve been working with linear formed fibre technology since 2012,” says David Kilpatrick. “Initially, we focused on round and non-round packaging for food applications, but liquids were always on our radar and the developments within the moulded fibre category led us to realise that we could adapt our expertise to create a fully functional threaded paper bottle.”
That realisation set the company on a multi-year journey of development and innovation, culminating in a solution that addresses the weaknesses of existing fibre-based bottles while offering a compelling alternative to traditional plastic and glass packaging.
Breaking the barrier
One of the biggest technical challenges in developing a paper bottle is achieving sufficient barrier properties to prevent moisture and oxygen ingress, while still maintaining a high fibre content. Typically, paper bottles rely on plastic liners, which can compromise recyclability.
Zipform’s approach is different, as Kilpatrick explains: “Our process applies a barrier layer in a way that avoids the need for a plastic liner. Instead of a separate layer of plastic, we use a technology similar to that used in a print process to apply a very thin barrier coating.”
This method ensures the bottle retains its liquid-holding capabilities while maintaining an impressive 95 per cent+ fibre composition. In fact, Kilpatrick says Zipform is already testing generation two and three materials, which push fibre content even further – beyond 97 per cent.
While some brands in Europe are producing fibre bottles with plastic bladders, Kilpatrick asserts that Zipform’s approach represents a world first in balancing high fibre content with barrier functionality.
Scalability for commercial success
Many fibre-based packaging solutions struggle with scalability – a critical barrier to commercial adoption. Zipform has overcome this challenge by leveraging multiple fibre technologies.
“We will see production speeds of more than 300 bottles per minute, compared to some existing fibre bottle technologies that take seconds per unit,” says Kilpatrick.
Further, the modular technology allows the company to adapt bottle sizes quickly, making it attractive to brand owners looking for a seamless transition from plastic to fibre-based solutions.
“Instead of investing in multiple sets of tooling for different bottle sizes, our process allows brands to produce multiple sizes with a single toolset, significantly reducing costs and complexity,” Kilpatrick adds.
Recyclability first
Zipform’s paper bottle has been engineered with recyclability at its core. Unlike other fibre bottle concepts that contain plastic components, Zipform’s design ensures an exceptionally high fibre yield in the recycling process.
“We’ve conducted extensive recyclability testing, and the results confirm that our packaging achieves excellent fibre recovery rates,” says Bigley.
Additionally, the bottle incorporates 50 per cent post consumer recycled content, a differentiating feature in the paper bottle space.
Kilpatrick, who serves on the Standards Australia Committee for fibre re-pulpability methodology, says the bottle will undergo CEPI recyclability testing in Europe, alongside the Australian standards test method.
“We are committed to meeting global recyclability benchmarks, ensuring that this innovation aligns with circular economy principles,” he explains.
Market applications
With technical challenges overcome and a scalable manufacturing process in place, the next question is: which industries will adopt the paper bottle first?
“We see major opportunities in non-carbonated beverages, dairy, and nutraceuticals,” says Bigley. “Nutraceuticals, in particular, rely heavily on plastic and glass packaging, and we believe this sector will be an early adopter of our solution.”
Kilpatrick also points to the potential for spices, seasonings, and dry goods, particularly as Zipform’s process allows for flexible height adjustments to suit various applications.
A future in fibre
Zipform Packaging’s commitment to advancing fibre-based solutions doesn’t stop at bottles. The company is actively exploring how its barrier technology could be applied to other formats, including trays, tubs, and even flexible packaging.
“We’re on a mission to push the boundaries of what’s possible with fibre,” says Bigley. “Fibre-based packaging offers a real, scalable alternative that aligns with sustainability goals and consumer demand.”
As Kilpatrick puts it: “The Zipform paper bottle is the first truly scalable alternative to plastic bottles, offering real-world recyclability and circularity – without compromising on functionality or performance.”
With global brands increasingly seeking sustainable solutions, Zipform’s breakthrough could redefine the future of beverage and nutraceutical packaging.
What’s next?
With trials for barrier performance now underway, Zipform plans to engage brand owners for market testing in the coming months. The company also aims to launch the bottle commercially in 2026, with production facilities potentially located both in Australia and globally, depending on customer demand.
“We’re at the final stages now,” says Bigley. “It’s taken us three years to get here, but we’re confident that this is the most viable paper bottle solution the market has seen.”
As the packaging industry continues to seek truly circular solutions, Zipform’s game-changing fibre bottle may well be the long-awaited breakthrough that brands and consumers have been searching for.
This article first appeared in PKN Packaging News, March-April print issue, page 24.
