Helping Rao’s® eliminate single‑use plastic from its multipack sauce jars

Rao’s wanted a plastic-free solution that met sustainability goals for the brand and Costco. But replacing plastic with paper-based packaging is not simply a material swap. The solution needed to work seamlessly within real production environments and scale from small pilot runs to high-speed manufacturing. Rao’s required flexibility to test the concept in-market, support manual repacking operations, and ultimately automate the process for higher-volume products—all while maintaining efficiency, ergonomics and product quality.

Our team worked closely with Rao’s to develop and refine solutions through a collaborative, step-by-step process to introduce Cluster-Clip®, a paper-based clip solution for multipacks. We began with Rao’s Alfredo sauce as a test case, designing a manual Cluster-Clip applicator that allowed operators to apply clips quickly and comfortably. Through rapid prototyping and continuous feedback, we tailored the tool to the production process and the people using it, enabling teams to pack up to 13,000 units per day at roughly 27 packs per minute. Once the concept proved successful, we advanced to a higher-volume application for Rao’s Marinara. To support this scale, we engineered a high-speed Cluster-Clip Fortuna® capable of folding and applying unglued fiber clips across a variety of product formats, delivering the automation and throughput needed for large-scale manufacturing.

The final solution gave Rao’s the speed, flexibility and scalability required to support growth in club retail channels while advancing its sustainability goals. By replacing plastic with a fiber-based Cluster-Clip, the new packaging makes the multipack easier to open and carry while eliminating single-use plastic – removing an estimated 210 tons of plastic annually from Costco alone. It also strengthens collaboration with retailers such as Costco, helping both organizations meet shared sustainability commitments. For us at Smurfit Westrock, this project demonstrates how close collaboration and packaging innovation can deliver solutions that elevate brands, improve the consumer experience and advance sustainability goals.