Boardio™ Sustainable Paper Packaging & Paper Bottle Solutions
Food manufacturers and health and wellness brands are under increasing pressure to reduce plastic packaging without sacrificing product protection, shelf life, operational efficiency, or shelf appeal. Boardio™ provides a recyclable, paper-based packaging solution designed to reduce dependence on traditional rigid plastic and metal containers while maintaining the performance brands need.
Made primarily from paperboard, Boardio™ combines a lightweight, semi-rigid structure with advanced barrier options that help protect products from oxygen and moisture. The format is easy to handle, stack, and ship, while integrated lid options provide convenient opening and reclosing for consumers.
For brands looking for sustainable food packaging, paper bottle packaging, or a lower-plastic alternative to conventional containers, Boardio™ offers a practical path forward.
What is Boardio™ Packaging?
Boardio™ is a paper-based packaging system designed as an alternative to traditional rigid plastic bottles, metal containers, and conventional paper canisters.
Its paperboard construction helps reduce the amount of plastic used in the package while providing the structure and barrier performance needed for a range of dry food, nutraceutical, and wellness products.
Compared with traditional paper canisters, Boardio™ can offer more advanced barrier options and integrated lids for easy open-and-close convenience.
- Paper-based construction
- Reduced plastic use
- Oxygen and moisture barrier options
- Lightweight, semi-rigid structure
- Integrated closure options
- Custom branding opportunities
- Display-ready packaging
- Formats suitable for bottles and canisters
Why Paper Bottle Packaging Matters
Packaging decisions increasingly affect more than product protection. Manufacturers must also consider sustainability goals, retailer requirements, transportation costs, material usage, and how packaging influences consumer perception.
Paper bottle packaging gives brands an opportunity to reduce reliance on rigid plastic while maintaining a package that is practical for production, shipping, retail display, and everyday use.
Boardio™ can help support packaging strategies focused on:
- Reducing plastic use
- Lowering packaging weight
- Improving sustainability positioning
- Supporting retailer sustainability initiatives
- Creating more distinctive shelf presentation
- Developing packaging around evolving consumer expectations
For food and nutraceutical brands evaluating alternatives to traditional plastic packaging, Boardio™ provides a format that balances sustainability with performance.
Why Choose Boardio™?
Boardio™ is designed to help brands improve packaging sustainability without creating unnecessary complexity in the production process.
Reduce Plastic Use
Boardio™ packaging can reduce plastic use by up to 80%, depending on the package configuration. Its paperboard-based structure provides an alternative for brands looking to move away from traditional rigid plastic containers.
Lightweight for Shipping and Handling
The lightweight structure can help reduce shipping weight and make products easier to stack, handle, and transport.
Protect Product Quality
Available barrier options help protect against moisture and oxygen, important considerations for many dry foods, powders, supplements, coffee, tea, and similar products.
Protect Product Quality
Available barrier options help protect against moisture and oxygen, important considerations for many dry foods, powders, supplements, coffee, tea, and similar products.
Support Consumer Convenience
Integrated lid options provide straightforward opening and reclosing for products that may be used over multiple occasions.
Support Custom Branding
Boardio™ can be customized to support branded, display-ready packaging and product launches.
Industries We Serve
Boardio™ is applicable across varied food, beverage, and wellness categories that prioritize packaging performance, sustainability objectives, and shelf differentiation. Such industries include:
- Food Manufacturing
- Nutraceutical Manufacturing
- Coffee Roasters
- Sports Nutrition
- Private Label Food Brands
- Natural Foods
- Organic Products
Common Boardio™ Packaging Applications
Boardio™ accommodates an array of dry-format products, with applications spanning nutritional powders, beverages, snacks, and specialty food ingredients. Common uses include:
- Coffee Packaging
- Tea Packaging
- Supplement Packaging
- Snack Packaging
- Dry Ingredient Packaging
- Protein Powder Packaging
Boardio™ vs. Traditional Plastic Bottles
For brands evaluating a plastic bottle alternative, Boardio™ provides a different balance of material use, weight, sustainability, and shelf presentation.
| Feature | Boardio™ Packaging | Traditional Plastic Bottles |
|---|---|---|
| Primary Material | Made primarily from paperboard with limited plastic components | Made primarily from rigid plastic |
| Plastic Use | Can reduce plastic use by up to 80%, depending on configuration | Relies primarily on plastic for the container |
| Recyclability | Designed as a recyclable, paper-based packaging alternative | Depends on resin type and local recycling availability |
| Package Weight | Lightweight, semi-rigid structure | Typically constructed from rigid plastic |
| Shipping Efficiency | Lower package weight may help reduce transportation weight | Heavier rigid containers can add shipping weight |
| Barrier Protection | Advanced oxygen and moisture barrier options are available | Commonly provides strong moisture and oxygen protection |
| Closure Convenience | Integrated lid options support easy opening and reclosing | Typically uses a separate cap or closure |
| Shelf Appearance | Natural paperboard appearance supports sustainability-focused branding | Conventional rigid plastic appearance |
| Custom Branding | Supports customized, display-ready packaging | Supports labels, sleeves, printing, and other decoration methods |
| Sustainability Positioning | Designed to support plastic-reduction initiatives | May be less aligned with brands focused on reducing rigid plastic use |
Sustainable Packaging Can Also Support Cost Savings
Reducing plastic does not necessarily mean increasing packaging costs.
For qualifying applications, Boardio™ may help simplify the packaging structure by replacing a traditional rigid plastic bottle, separate cap, and label with a paper-based package that integrates more of the finished package into a single format.
Using the example cost model below, that difference can create meaningful savings at production scale.
Example Packaging Cost Comparison
| Packaging Component | Traditional Plastic Packaging | Boardio™ Paper-Bottle |
|---|---|---|
| Bottle / Container | $0.30 | $0.30 |
| Cap | $0.15 | Included in modeled package |
| Label | $0.10 | Included in modeled package |
| Estimated Total Cost Per Unit | $0.55 | $0.30 |
| Estimated Savings Per Unit | — | $0.25 |
What Could $0.25 Per Unit Mean at Scale?
At higher production volumes, even a modest per-unit difference can have a substantial impact on the total packaging program.
- 200,000 units: approximately $50,000 in estimated savings
- 5 million units annually: approximately $1.25 million in estimated annual savings
For food, nutraceutical, and wellness brands evaluating sustainable packaging, this creates an important opportunity: reducing rigid plastic may support both environmental goals and packaging economics.
Look Beyond the Cost of the Container
The total cost of a packaging program can include more than the unit price of the package itself. Manufacturers should also consider:
- Caps and closures
- Labels and decoration
- Filling and assembly
- Secondary packaging
- Shipping weight
- Storage requirements
- Pallet efficiency
- Labor
- Material handling
Boardio™ should therefore be evaluated as part of the complete packaging program—not simply as a one-to-one container replacement.
Share your current bottle, closure, label, annual volume, and packaging costs with CTI. Our team can help evaluate whether Boardio™ could provide a more sustainable and cost-effective alternative for your product.
Cost figures shown are example estimates and may vary based on package size, materials, decoration, order volume, product requirements, and other program specifications. CTI can provide project-specific pricing after reviewing your application.
Boardio™ Packaging at CTI
Working with Combined Technologies, Inc. gives brands access to Boardio™ packaging within a facility equipped to support both primary and secondary packaging services.
CTI can help integrate Boardio™ into a broader packaging program that may include filling, secondary packaging, design support, supply chain coordination, and fulfillment.
Benefits of working with CTI include:
- In-house Boardio™ packaging capabilities
- Support for both paper bottle and canister formats
- Scalable production for smaller and higher-volume programs
- Custom branding and display-ready packaging opportunities
- Primary and secondary packaging capabilities
- Experience serving health and wellness brands
- Packaging design and supply chain support
- Fulfillment capabilities
Boardio™ Packaging at CTI
Working with Combined Technologies, Inc. gives brands access to Boardio™ packaging within a facility equipped to support both primary and secondary packaging services.
CTI can help integrate Boardio™ into a broader packaging program that may include filling, secondary packaging, design support, supply chain coordination, and fulfillment.
Benefits of working with CTI include:
- In-house Boardio™ packaging capabilities
- Support for both paper bottle and canister formats
- Scalable production for smaller and higher-volume programs
- Custom branding and display-ready packaging opportunities
- Primary and secondary packaging capabilities
- Experience serving health and wellness brands
- Packaging design and supply chain support
- Fulfillment capabilities
Frequently Asked Questions (FAQs)
What is Boardio packaging?
Boardio™ is a paper-based packaging system designed as a more sustainable alternative to traditional rigid plastic and metal containers. Made primarily from paperboard, Boardio™ combines a lightweight and semi-rigid structure with moisture and oxygen barrier options to help protect products while significantly reducing the amount of plastic used in the package.
Is Boardio recyclable?
Yes, Boardio™ packaging is recyclable. Its paperboard-based construction can greatly reduce the amount of plastic required compared with conventional rigid plastic packaging. Recycling acceptance and instructions may vary depending on the specific package configuration and local recycling infrastructure.
Can Boardio replace plastic bottles?
Yes, Boardio™ can provide an alternative to rigid plastic bottles for many dry food, beverage, and nutritional products. Brands can reduce their reliance on plastic while maintaining important packaging features such as product protection, ease of use, and strong retail presentation.
What products work best in Boardio?
Boardio™ is particularly well suited to dry products that benefit from protection in a lightweight, paper-based format. Common applications include protein powders, nutritional supplements, coffee, tea, powdered beverages, snacks, confectionery products, and dry food ingredients. CTI can evaluate product characteristics, barrier needs, and packaging requirements to determine whether Boardio™ is a strong fit for a given application.
Does Boardio provide moisture protection?
Yes. Boardio™ packaging can incorporate barrier protection to help protect dry products from moisture and maintain product quality. The appropriate barrier configuration is contingent on factors such as the product, desired shelf life, storage conditions, and other packaging requirements.
Does Boardio have oxygen barriers?
Yes. Boardio™ can be configured with oxygen barrier properties to help protect oxygen-sensitive products. Barrier requirements vary by product, so the appropriate Boardio™ structure should be selected based on the product's specific protection and shelf-life needs.
Is Boardio food safe?
Yes. Boardio™ is food safe when the appropriate food-contact materials and package specifications are used. CTI maintains strict food safety and quality programs, including SQF Level 2, 21 CFR Part 111, cGMP, and Organic capabilities, along with HACCP, allergen control, raw material inspection, and product monitoring programs.
Can Boardio be custom printed?
Yes. Boardio™ can be custom printed with brand graphics, product information, and other design elements. Its broad paperboard surface accommodates more sophisticated visual treatments and detailed brand communication, helping create packaging with a distinctive, retail-ready presence.
What industries use Boardio?
Boardio™ packaging is suitable for a myriad of food, beverage, nutrition, and wellness markets. Potential applications include food manufacturing, nutraceutical manufacturing, coffee roasting, sports nutrition, private-label foods, natural foods, and organic products.
Can CTI fill Boardio containers?
Yes. Combined Technologies, Inc. (CTI) offers Boardio™ filling and packaging capabilities at our Bristol, Indiana facility for suitable products. With both primary and secondary packaging services available in-house, we can incorporate Boardio™ containers into a broader contract packaging program, from filling through finished, retail-ready packaging.
Why Partner With CTI?
Choosing a sustainable package is only part of the challenge. Manufacturers also need a partner that can help move the package from concept into production.
CTI combines Boardio™ capabilities with experience in:
- Contract filling
- Food-grade packaging
- Dry packaging
- Gummy bottling
- Pouching
- Cartoning
- Kitting
- Packaging design
- Supply chain management
- Fulfillment
- Retail and sales displays
This allows brands to evaluate Boardio™ as part of a complete packaging program rather than as a standalone container.
Ready to Explore Boardio™ Packaging?
If your company is looking for a recyclable paper packaging solution, evaluating alternatives to rigid plastic bottles, or planning a more sustainable product launch, CTI can help determine whether Boardio™ fits your requirements.
Tell us about your product, current package, production volume, and sustainability goals. Our packaging team can review the application and help identify the next step.