In the following Q&A, Laëtitia Durafour, Marketing Director at Sonoco Metal Packaging EMEA, discusses the development of Horizon™, a sustainable metal packaging solution. She shares insights on how this innovative product addresses evolving consumer expectations and regulatory changes in the packaging industry, its unique recyclability benefits, and Sonoco’s approach to balancing sustainability with product performance. Durafour also explains the broader environmental impact of metal can manufacturing and the opportunities for creating a circular economy through industry collaboration.

What inspired the development of Horizon™, and what sustainability challenges does it address?

“The evolution of Horizon™ has been driven by several elements – primarily our commitment to creating a more sustainable future for the food and packaging industry. This commitment is paired with our unwavering dedication to improving the sector’s sustainability trajectory and our passion for endless innovation, which is in our DNA at Sonoco. 

“Like many sectors, the food and packaging industry is navigating evolving consumer expectations and managing complex legislative changes. These changes are causing many organisations to respond quickly. The incoming wave of regulatory developments, including the Packaging and Packaging Waste Regulation (PPWR) and Corporate Sustainability Reporting Directive (CSRD), are increasingly changing the landscape we’re working in. As we navigate these changes, we are conscious that our clients need to meet these evolving expectations. Our innovations, like, Horizon™, can help support our clients in meeting these changing legislative requirements.” 

What makes Horizon™’s single-material metal design a game-changer for recyclability?

“Insights from a recent Deloitte report show that 61% of shoppers are actively looking to limit their usage of single-use plastics, and 68% are focused on reducing food waste*. Businesses need to look into products and services that meet these needs. 

“Horizon™ is the first of its kind and an innovation that is pushing the boundaries of lightweight sustainable packaging. The new shallow metal overcaps are industry-leading, eco-conceived with less material and an ultra-shallow design, offering all food markets (dry and wet) an ultra-light weight, modern, and infinitely recyclable cap for cans.  Horizon™ offers customers a product that will satisfy the changing environmentally conscious mindsets of end consumers.”

How does Sonoco Metal Packaging EMA balance sustainability with maintaining product protection and performance?

“Finding a balance between product protection and performance is key. Our core focus at Sonoco is on using circular materials and energy-efficient manufacturing practices to reduce our carbon footprint. By investing in state-of-the-art equipment, we’re able to reduce our greenhouse gas emissions during the production process. Our commitment to sustainability includes developing innovative products that further extend lifespan while minimising waste. Our partnership approach with suppliers, clients and trade associations helps drive circularity throughout the value chain. Alongside our efforts in reducing secondary packaging and reducing raw material use, we contribute to a more sustainable packaging lifecycle while maintaining high standards of product protection and performance.”

How can advancements in metal can manufacturing contribute to reducing the environmental impact of packaging, and what role does recycling play in this process?

“At Sonoco, we engineer packaging that maximises lightweighting while safeguarding the integrity of the pack, significantly reducing the amount of raw material needed. This approach is the primary lever in sustainable innovation, exemplified by Horizon™ – the result of decades of collaboration between our marketing team, the new product development team in Châtillon-sur-Seine, and our research and development centre in Wantage. Preserving resources and reducing CO2 emissions are at the heart of our innovation. One standout example is Ecopeel™, which lowers CO2 emissions by 20% compared to a standard three-piece food can while preserving raw material.

The second lever focuses on minimising energy consumption and greenhouse gas emissions during production. By leveraging Sonoco’s extensive network of metal packaging laboratories across EMEA, we continuously explore and implement the best technologies to maximise the lifespan of cans. One practical example is the combination of our Horizon™ metal cap with Easy Open End technology on hermetic cans. This solution not only extends the shelf life of dry products by protecting them from light and air but also enhances convenience with a reclosable feature after the first use – all within circular packaging that meets the demands of modern consumers. 

“Metal is a permanent material that is efficiently recycled today and can be recycled without material degradation Recycling preserves natural resources by reducing the need for new raw materials and energy usage compared to producing new metal. This process also lowers greenhouse gas emissions, contributing to climate change mitigation.”

What are the key challenges and opportunities in creating a circular economy for metal cans, and how can industry stakeholders collaborate to overcome these challenges?

“The circular economy for metal cans is already well-established, as steel cans are one of the most recycled packaging materials globally, with recycling rates often exceeding 80%. In fact, steel cans have already reached the ambitious 2030 targets outlined in the proposed Packaging and Packaging Waste Regulation (PPWR). This success story demonstrates the inherent advantages of metal packaging – its endless recyclability without loss of quality and the well-developed infrastructure that supports it. 

However, there are still challenges that require collective industry effort to further optimise the system and ensure long-term sustainability. One key challenge is maintaining high recycling rates across all European countries. While some markets have already achieved impressive results, others still need to improve their collection and recycling systems. Industry stakeholders, including packaging manufacturers, recyclers, brand owners, and policymakers, must collaborate to harmonise best practices, invest in modern recycling infrastructure, and increase public awareness of metal recycling’s benefits. 

In terms of opportunities, the circular economy model offers immense potential to enhance brand value. Brands can clearly communicate the recyclability and circularity of their packaging, building consumer trust and loyalty. Ultimately, collaboration with supplier and customers is key. By aligning goals and pooling resources, industry stakeholders can reduce packaging waste, delivering packaging solutions that meet both regulatory requirements and consumer expectations while actively contributing to a more sustainable future.”