Bag-in-Box vs HDPE Jerry Cans: Which Packaging Solution Is Best for Liquid Products?

Date: 10/06/2026
Category: General

As manufacturers seek to reduce packaging waste, improve logistics efficiency and meet sustainability targets, many are evaluating alternatives to traditional HDPE jerry cans.

Bag-in-Box (BIB) packaging has become an increasingly popular solution across food, beverage, chemical and industrial sectors, but how does it compare to HDPE jerry cans in terms of material usage, transport efficiency, product protection and overall performance?

This guide compares both packaging formats to help you determine the benefits of each.

What is an HDPE Jerry Can?

A jerry can is a rigid container manufactured from High-Density Polyethylene (HDPE). They are commonly used for storing and transporting liquids including:

Typical sizes range from 5 litres to 25 litres, with 20-litre jerry cans being among the most widely used formats.

Cleaning chemicals
Food ingredients
Oils and lubricants
Agricultural products
Industrial liquids

What is a Bag-in-Box System?

A Bag-in-Box system consists of:

A flexible multilayer barrier bag

A dispensing fitment or tap

A corrugated outer carton

The liquid is stored within the bag, which collapses as product is dispensed, helping to minimise air ingress and product waste.

Bag-in-Box solutions are widely used for:

Dairy products
Liquid egg
Post-mix syrups
Wine and beverages
Cleaning chemicals
Industrial ingredients

Material Usage Comparison

One of the most significant differences between the two formats is the amount of plastic required.

The figures below represent typical packaging weights and may vary depending on design specifications.

Capacity	Typical HDPE Jerry Can Weight	Typical Bag-in-Box Bag Weight	Plastic Reduction
5L	120-180g	20-40g	Up to 80%
10L	250-350g	40-60g	Up to 85%
20L	700-900g	80-120g	Up to 90%
25L	900-1,200g	100-140g	Up to 90%

Example: 20-Litre Format

For every 1,000 units filled:

HDPE Jerry Cans

Approximate plastic consumption: 700-900 kg

Bag-in-Box Liners

Approximate plastic consumption: 80-120 kg

Potential plastic saving:
580-820 kg per 1,000

This reduction can have a significant impact on sustainability objectives and packaging costs.

Warehouse Space Requirements

Rigid containers occupy the same volume whether empty or full.

Bag-in-Box liners are supplied flat-packed, either webbed or singles dependant on the filling method allowing thousands of units to be stored in a fraction of the space required for empty jerry cans.

Typical Example

Approximately 1,000 empty 20L jerry cans may require up to 8-12 pallets spaces – The equivalent number of Bag-in-Box liners can often be stored on a single pallet.

Benefits include: