How Warped Wing is Saving Money While Being Sustainable in This Packaging Switch

Courtesy Warped Wing Brewing

Warped Wing is in the process of making strides towards becoming more sustainable with a switch to biodegradable six-pack can carriers. This decision, driven by a pair of goals of cost-effectiveness and environmental responsibility, is a way the Dayton, Ohio brewery is looking to show commitment to innovation while also being more mindful in business practices.

“This all started as part of a routine evaluation of our vendors and their products,” said John Haggerty, Brewmaster at Warped Wing. “It’s our responsibility as leaders to regularly perform market checks, especially with the pressures businesses face around costs of goods, labor, and more. 

“Initially, we were simply exploring a more cost-effective option for our six-pack carriers. What we found was not only more affordable but also more environmentally friendly.”

The brewery collaborated with Roberts PolyPro, the supplier of the new Craft-Pak Versa carriers, to ensure they met Warped Wing’s operational standards. 

“We ran tests over the past four or five months to clear three key hurdles,” Haggerty said. “The new rings had to work without issue, function seamlessly with our current applicator, and allow us to switch back to our previous carriers if needed.”

The switch to these sustainable six-pack carriers showcase how any brewery can balance operational efficiency with environmental stewardship and provide others in the industry a model to follow.

With minor tweaks to both the carriers and the existing applicator, Warped Wing has achieved compatibility and is moving forward with the rollout after a market test with one brand in January.

“Roberts PolyPro adjusted the rings to make them robust and efficient on our system. They also helped us refine the applicator, which improved performance for both the old and new carriers,” Haggerty said.

From a marketing perspective, the new carriers align well with the brewery’s values. 

“These carriers are 100% biodegradable,” said Tara Spoores, Marketing Director at Warped Wing. “According to the manufacturer, they undergo rigorous testing under landfill conditions and fully biodegrade within 56 weeks.”

Spoores noted that while the new carriers also hold up well under refrigeration, moisture, and transportation, Warped Wing is currently rolling them out on a single SKU as they work through existing inventory of traditional carriers. 

READ MORE: Malt Storage Q&A: Warped Wing’s John Haggerty

“We’ve seen no performance issues so far, and our production team has collaborated closely with the supplier to ensure a seamless transition,” Spoores said.

The cost savings from the new carriers, which Haggerty estimates at around 20%, make the switch even more appealing. 

“This really feels like a win-win for everyone,” Spoores said. “They’re less expensive and more environmentally friendly, which aligns with what we and our customers value.”

As for disposal, the biodegradable carriers can be discarded as regular waste. However, Spoores explained that having consumers returning carriers for reuse is not practical for Warped Wing due to the brewery’s automated application process and the need for thorough sanitation of reused materials.

The brewery’s final steps before fully implementing the new carriers include selecting a ring color and ensuring customer acceptance. 

“Our marketing team is doing a final check to make sure customers are on board,” Haggerty said. “Once that’s done, we’re ready to move forward.”

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