A New Step Towards the 100% Circular Drum

What if the future of industrial packaging began with something as commonplace as a lid?

At Joaquín Alberto S.A., we believe that sustainability is not measured in speeches, but in millimetres of cardboard, in recovered materials and in design decisions that truly change the way we manufacture.

That is why we have developed the new ECO-Kraft drum, a container redesigned to reduce its environmental impact, improve its technical performance and move towards a goal that has guided us for years: a 100% circular drum.

Eco-design to transform

The most significant innovation in the new ECO-Kraft drum lies in a detail that could easily go unnoticed: its lid.

Thanks to our collaboration with OiKo Design Office, we have developed a lid made from Tetra Pak waste, a solution that allows us to reuse post-consumer materials and give them a new lease of life within the packaging industry.

This project was created with a dual purpose:

Reduce the carbon footprint associated with the manufacture of the drum.
Increase your circularity index, ensuring that each component can be reincorporated into the production cycle.

From waste to performance: a lid with a purpose

The technical challenge was considerable. Conventional caps for 50-litre drums are made from virgin polypropylene and, in most cases, cannot be properly recycled.

Furthermore, in standard models, metal reinforcements make it difficult to separate materials at the end of their useful life.

The new cap, made from recycled Tetra Pak packaging plastic (PE+PP), has achieved the following:

Replacing steel with structural cardboard reduces metal usage by 75%.
Reduce the total weight of the drum by 9.4%.
Increase renewable content by 24.4%.
Double the circularity index, reaching 87.3% compared to 43.8% for the standard model.
And, most importantly, reduce the carbon footprint by 41.8%.

These results confirm that sustainability does not have to compromise the strength or safety of packaging.

Technical validation: guaranteed safety and stackability

The new design was subjected to drop tests from 120 cm with a load of 36 kg, simulating real handling and transport conditions.

The results were clear: the cap + container system maintained the integrity of the assembly, without coming loose or losing any contents, complying with the regulatory requirements of the sector.

In addition, the new geometry of the lid, with a raised central body and radial ribs, allows for stable stackability, improving safety in storage and transport.

This feature offers an immediate logistical advantage for industrial customers who work with high volumes of packaging.

Prototyping and domestic manufacturing

Initial prototyping was carried out using 3D printing (FDM), which allowed details to be adjusted and compatibility with the metal leaf spring closure system to be validated.

Following the testing phase, an injection mould was developed that was adapted to the recycled material and compatible with the equipment at our partner plant, Diroca, ensuring controlled and efficient domestic production.

Large-scale manufacturing envisages the production of 400,000 units per year, using recycled material supplied by OiKo.

Each cap manufactured represents a tangible step towards a more responsible industrial economy.

A measurable environmental impact

Beyond visual or conceptual improvements, the project has been measured using Life Cycle Assessment (LCA) criteria, comparing the new ECO-Kraft drum with the standard model.

The results are compelling:

Indicator	Standard drum	ECO-Kraft	Variation
Carbon footprint (kg CO₂)	3,47	2,02	−41,8 %
Circularity index	43,8 %	87,3 %	+99 %
Material lost at the end of its life	90,6 %	20 %	−77,9 %
Renewable content	60,6 %	75,4 %	+24,4 %

If we project these figures to an annual production of 400,000 drums, the environmental savings are significant:

580 tonnes less CO₂ emissions.
766 tonnes less waste generated.
88 tonnes less materials used.

The result: lighter, more efficient packaging with a lower climate impact.

Applied circularity: from design to end of life

The ECO-Kraft drum has been designed to be easily recycled.

Its composition, cardboard, recycled plastic and a small proportion of galvanised steel, allows the materials to be easily separated in conventional recycling plants.

While a standard drum usually ends up in a landfill, the new design achieves an estimated 80% recycling rate, drastically reducing waste destined for disposal.

In this way, we close the cycle: from waste to product, and from product to recycling.

Technology and responsibility: our roadmap

The development of this cover marks the beginning of a broader plan within our innovation strategy.

At Joaquín Alberto, we have defined a technological roadmap to continue reducing emissions and improving the environmental performance of our entire range of packaging:

Product development: apply the ECO-Kraft model to all sizes and versions of drums.
Advanced manufacturing: implementation of new injection moulds adapted to recycled materials.
Performance tests: resistance, impermeability and sound absorption tests in accordance with ADR and UN regulations.
Industrialisation of structural cardboard rebonding, eliminating the use of stamped steel.
Continuous life cycle assessment to accurately measure environmental improvement in each production line.

Each of these actions is part of Joaquín Alberto’s commitment: manufacturing in Spain, with real innovation and verifiable sustainability.

Benefits for the industry

The new ECO-Kraft drum is not just an environmental improvement; it is a competitive advantage for our customers.

Sectors that require approved packaging, such as the chemical, pharmaceutical, agri-food, and cosmetics industries, will find this model to be a solution that combines:

ADR and UN regulatory compliance.
Structural safety validated through testing.
Weight reduction to optimise logistics costs.
Sustainable brand image, consistent with the demands of its own customers and distributors.

Furthermore, the use of recycled and recyclable materials improves the environmental traceability of the final product, facilitating communication in sustainability reports or ESG reports.

Contact our technical team

Would you like to know how to apply this innovation to your packaging line or reduce the environmental impact of your logistics?

Contact our technical team and discover how we can help you move towards safer, more efficient and circular packaging.