DS Smith partners Carlsberg Britvic to launch upgraded bag-in-box packaging

UK – DS Smith has collaborated with Carlsberg Britvic to launch an enhanced OTOR8 Bag-in-Box design, representing the first step in their joint effort to streamline the beverage company’s supply chain while prioritizing environmental gains. 

This upgrade transitions from the previous OTOR4 model to an eight-sided structure that boosts durability and packing efficiency.

The redesigned packaging permits an average of 25% more boxes on each pallet, which decreases the total number of pallets and trucks needed for shipments along the 115-mile path from Carlsberg Britvic’s Leeds manufacturing facility to its Lutterworth distribution center. 

As a result, the initiative is set to eliminate over 50 tonnes of CO2 emissions each year from transport activities.

Beyond emissions savings, the OTOR8 design improves warehouse utilization by conserving storage space, lowers the chance of product leaks, and offers better stability due to its vertical orientation. 

These features address key operational challenges in handling soft drinks for pubs, bars, and restaurants.

In a statement, Liz Manuvelpillai, Sales, Marketing, and Innovation Director at DS Smith, said, “We’re thrilled to have delivered an effective packaging solution in collaboration with Carlsberg Britvic.”

“Our innovation will see fewer consignment vehicles on the road, lower transport emissions, and contribute to supply chain efficiency.”

Carlsberg Britvic’s Sustainability Director, Tom Fiennes, highlighted the packaging’s role in their operations, explaining that the company manufactures more than 25 million liters of soft drinks annually, including brands like Pepsi MAX, 7UP, Tango, and R. White’s lemonade. 

He added that the new design provides sturdier options for customers and marks another step toward net zero emissions.

The beverage firm has demonstrated ongoing commitment to carbon reduction through substantial investments. 

Over the past three years, it has allocated more than US$12 million to technologies that curb emissions at its UK soft drink factories. Additionally, 75% of the grid electricity powering these sites comes from solar panels.

Recent developments show DS Smith advancing its sustainability agenda following its acquisition by International Paper on January 31, 2025. 

According to reports, this US$7.2 billion deal has combined forces to form a major player in fiber-based packaging across North America and Europe, Middle East, and Africa regions. 

The merger included divestitures of several European plants to meet regulatory requirements, enabling focused growth in eco-friendly solutions.

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