Packaging company Huhtamaki North America has introduced a new line of sustainable moulded fibre-based cartons for use by egg producers in the US.

Produced using 100% recycled material, these new cartons have been developed as an alternative to conventionally used polystyrene foam in the egg market.

Currently, 12 states in the country have enacted legislation to prohibit the use of expanded polystyrene packaging.

The material is commonly used for making foam ‘peanuts’ used to cushion packaging, as well as for coolers, foodservice cups and plates, and egg packaging.

Last year, Huhtamaki announced plans to invest $100m to expand its 250,000ft² moulded fibre manufacturing plant in Hammond, Indiana, US.

The company’s advanced technology will enable the production of a full range of customisable fibre-based egg cartons, the materials of which are sourced in North America.

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The cartons will also provide more space for branding on clients’ packaging and come in various colours.

Huhtamaki North America sales manager Tyler Hodges said: “We expect the demand for egg cartons in the US to reach 4.3 billion packs in 2025.

“The market size presents a great opportunity for the egg producers looking to shift to fibre-based egg cartons ahead of legislation and bans on polystyrene foam packaging.

“Huhtamaki’s experience with moulded fibre product design and operations is extensive worldwide and we will fully leverage this for the needs of the US market.”

In July this year, Huhtamäki reported net sales of €1.05bn ($1.169bn) in the second quarter of financial year 2023, a decrease of 8%.