In pursuit of continuous improvement and waste reduction, Sierra Nevada Brewing Co. evaluated opportunities to eliminate single-use materials across its operations. After previously discontinuing disposable kraft paperboard slip sheets as part of a cost and sustainability initiative, a new need emerged with the introduction of automated variety pack lines, where protective top sheets became necessary to maintain product integrity.  

To address the challenge, Sierra Nevada partnered with Charter Next Generation (CNG) to implement a reusable, high-performance alternative. The result: significant waste reduction, lower operating costs, and improved production efficiency, reinforcing the brewery’s closed-loop philosophy while strengthening operational performance. 

The Material Challenge 

At its LEED Platinum–certified brewery in Fletcher, North Carolina, Sierra Nevada Brewing Co. has long advanced sustainability across operations, from closed-loop energy systems to water reuse and waste reduction. While evaluating its high-throughput variety pack production line, the team identified the need for a new, higher-quality slipsheet solution to replace the previously discontinued kraft paperboard sheets and serve as a longer-lasting protective layer. 

Though effective, paperboard sheets typically require frequent replacement. Their short lifespan leads to more changeouts and downtime, higher material consumption, and recurring waste. The brewery sought a more durable, scalable, and sustainable solution compatible with its automated, high-cycle production environment. 

The Sustainable Solution 

To address this challenge, Sierra Nevada partnered with CNG to implement reusable polyethylene (PE) slip sheets made with recycled content and engineered for long-term durability and repeatable handling. The reusable sheets were a direct upgrade in performance over previously used materials and integrated seamlessly into existing production workflows. 

The new system delivered immediate performance and environmental benefits: 

• Maintains strength across many cycles of use over kraft paperboard 
• No end-of-life threshold reached to date 
• Seamless integration into existing production processes 

By leveraging a highly durable, recycled-content material that functions as a long-life asset, Sierra Nevada reduced waste and improved operational efficiency, demonstrating that sustainability and performance can advance together.

The Material Impact 

Over two years, the use of PE slip sheets generated measurable material, financial, and operational benefits:  

• 7–8x lower cost per use compared with disposable kraft 
• 98% reduction in sheet consumption  
• 87% reduction in direct material cost  
• Reduced material handling, purchasing, and changeout frequency 
• Proven durability in high-cycle automated production environments

Beyond direct savings, the reusable system improved pallet stability, reduced handling labor, and eliminated thousands of disposable sheets from the waste stream, all while supporting Sierra Nevada’s broader circularity and reuse objectives. 

Looking Ahead: A Model for the Scalable Circularity 

Sierra Nevada’s success demonstrates the broader potential of reusable material systems across beverage and manufacturing operations. By replacing single-use materials with durable, recycled-content solutions, manufacturers can: 

• Dramatically reduce waste and material consumption  
• Improve consistency and durability in automated operations 
• Advance sustainability goals without sacrificing performance 
• Convert disposable inputs into long-term operational assets 

 As CNG continues advancing sustainable material solutions, partnerships like this exemplify how innovation at the material level can help leading brands deliver measurable progress toward sustainability commitments, further Enhancing Lives for a Better World through smarter, more efficient systems.