The Energizer Packaging Transformation: There's More

Watch the video of our Director of Customer Innovation, Jonas Capistrant, talk about the Energizer story.

He'll describe how Aagard responded to Walmart challenging Energizer to transition away from plastic packaging; The task extended far beyond simply changing materials. It required total system-level innovation — a rethinking of formats, consumer usability, and end-to-end packaging automation. Energizer turned to Aagard to engineer a packaging transformation capable of meeting the sustainability mandate and elevating the consumer experience.

Aagard partnered directly with Energizer’s sales, marketing, engineering, and plant teams to reimagine the entire household battery platform. Every SKU size. Every format. Every touchpoint in the consumer journey. The result? A fully recyclable packaging family that is more intuitive, easier to open, better at protecting and organizing product, and optimized for automated production.

A key breakthrough was the development of a new upright case that maintains product orientation even as inventory is removed. For high-turn SKUs, this stability is essential. Engineers also introduced easy-tear features that let consumers open sleeves cleanly, access only the batteries they need, and avoid the familiar “22 loose batteries in a drawer” problem. Multi-carton sleeves allow packs like a 24-count to stay neatly contained long after first use.

To bring this innovation to life, Aagard designed a turnkey line integrating unloading, cartoning, sleeving, case packing, palletizing, stretch wrapping, and AMR interfacing. One continuous system — purpose-built for efficiency, accuracy, and operational safety. AMR traffic is intentionally isolated from operator areas, ensuring smooth, predictable flow at every stage.

This project demonstrates what’s possible when a sustainability challenge is met with engineering creativity. The solution didn’t just remove plastic; it delivered a packaging ecosystem that is smarter, stronger, more functional, and fully automated.

At Aagard, this is how we solve complex problems — with collaboration, inventive thinking, and technology built to scale.

Have a sustainability, space, safety, or efficiency requirement? We're here for it. We can't wait to partner with you. Contact us today.

Contact Aagard