Energizer Holdings has taken a bold step towards sustainable packaging with the launch of its new 100% recyclable, plastic-free battery packaging. This innovation marks a significant shift not only in material use but also in the machinery and processes behind its production. The transformation, developed in partnership with automation specialist Aagard, underscores Energizer’s commitment to sustainability and operational excellence.

The initiative began with a clean-slate approach—eschewing modifications to existing systems in favor of building entirely new packaging lines. Energizer’s new packaging strategy covers primary, secondary, and tertiary formats, all redesigned to eliminate plastic (excluding seals) and enhance recyclability. These efforts culminated in a comprehensive overhaul of the company’s Asheboro, North Carolina facility, with new machines rolled out progressively since late 2024.

New Paper-Based Format Replaces Plastic

The most visible change is the transition from thermoformed blisters to paper-based cartons and sleeves. This move is expected to remove roughly 2.5 million pounds of plastic annually from Energizer’s operations. The first wave of this packaging is already available at Walmart stores and online, with more retail partners onboarding through 2025. Ultimately, over 90% of Energizer’s North American portfolio will be covered.

Collaboration-Driven Innovation

The success of this transformation hinged on deep collaboration between Energizer and Aagard. From early-stage concepting through to execution, teams worked together to design systems capable of handling a wide range of battery types—AA, AAA, 9V, C, and D—on versatile U-shaped packaging lines. According to Hugh Belgarde, Energizer’s Senior Director of NA Battery Operations, involving Aagard from the start enabled the machinery builder to contribute directly to material and design iterations.

“We made the right call by bringing Aagard in early. This was about creating a new manufacturing platform from the ground up.” — Hugh Belgarde

Flexible, High-Efficiency Packaging Lines

Each line includes six main modules: tray depalletizer, tray unloader, cartoner, sleever, case packer, and palletizer/stretch wrapper. Energizer emphasized quick format changeovers, a goal achieved through Rockwell’s ASEM 6300B HMI platform combined with FactoryTalk Optix. On-screen adjustments and precision hand cranks enable rapid reconfiguration, improving line responsiveness to shifting market needs.

A standout component is the gantry-style robot equipped with a Gocator vision system. This robot handles battery trays using magnets and precision clamping, ensuring seamless and accurate transfer to downstream operations. From there, batteries travel through a vertical track-and-gravity feed system to a star wheel that meters them into cartons based on pack configuration.

Design for Shelf Impact and Shopper Clarity

One design challenge was maintaining brand identity and shopper trust without plastic windows. The team preserved key visual cues like the Energizer Bunny and clear battery count indicators. In a 16-count AA battery pack, for instance, the design uses both text and graphics to highlight quantity, retaining a sense of visibility.

Two unit-of-sale formats are now produced: hang-tab cartons for top-selling SKUs, and cartons inside sleeves for others. This consistency improves shelf impact and simplifies planogram development for retail partners. Energizer was deliberate about standardizing pack heights across small, standard, and large SKUs to ease planogram creation and improve shopper navigation.

“We wanted to guide shoppers through the shelf set while also making it easier for our retail partners.” — Kori Mizerny, Marketing Director

Retail-Ready Cases and Logistics Gains

All packaging lines output retail-ready corrugated cases designed for easy in-store display or pegboard hanging. These cases are perforated for quick opening, aligning with retailers’ operational needs.

With scalable machinery and sustainable packaging formats in place, Energizer has positioned itself as a leader in responsible manufacturing. As the company rolls out these innovations across its full portfolio, it sets a new benchmark for the battery industry’s environmental performance.

The plastic-free future is no longer a goal—it’s Energizer’s new reality.