Disruptive Packaging opened a new manufacturing and recycling facility in Mexicali, Mexico, strengthening Disruptive Packaging’s North American footprint and sustainable supply chain strategy. Company executives, local officials, and industry partners gathered Feb. 18 to mark the milestone.
The expansion positions Disruptive Packaging to meet rising demand for reusable and recyclable packaging across the fresh produce, seafood, meat, and poultry sectors. Moreover, the facility supports faster delivery and greater regional flexibility under the U.S.-Mexico-Canada Agreement.
Company leaders say the investment reflects a long-term strategy to build resilient, tariff-free operations while accelerating the adoption of URTHCOR®, its proprietary material.
State-of-the-Art Facility Drives Regional Growth
The 80,000-square-foot facility features two fully operational production lines designed to serve customers throughout the United States, Mexico, and Canada. By locating production near the U.S. border, Disruptive Packaging reduces transit times and lowers logistics costs.
The plant currently produces up to 20 million boxes and has expansion plans underway. In addition, the site houses some of North America’s largest bespoke extruders, corrugators, die cutters, laminators, and specialty and straight-line gluing machines.
Executives built the Mexicali operation to support tariff-free supply chains and protect customers from cross-border volatility. As a result, clients gain speed-to-market and reliable access to sustainable packaging solutions.
The company also installed patented technologies, including URTHCOR® boxes, corner angle systems, and pallet designs. These features help improve durability, stackability, and performance across demanding cold-chain environments.
To ensure operational excellence, Disruptive Packaging assembled a senior management team and technical specialists in Mexicali. The group works alongside global production and technical leaders to maintain consistent quality standards across markets.
Sustainability at the Core of Disruptive Packaging
Disruptive Packaging centers its strategy on sustainability. Demand continues to grow for alternatives to waxed cardboard and expanded polystyrene (EPS). Many of those materials create higher lifecycle emissions and resist closed-loop recycling.
URTHCOR® offers a different approach. The material blends high-density polyethylene and calcium carbonate to create waterproof, reusable, and closed-loop recyclable packaging.
According to company data, the material produces 80% less carbon dioxide than conventional waxed cardboard and EPS. Furthermore, the Mexicali facility includes a dedicated on-site recycling line. That system converts production scrap and end-of-life packaging into new recycled material.
“Sustainability is at the heart of everything we do,” said Brandon Penn, group joint CEO of Disruptive Packaging. He added that the facility integrates sustainable manufacturing processes while supporting customers’ environmental goals.
By embedding recycling into daily operations, Disruptive Packaging strengthens circularity and reduces waste across the supply chain.
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Enhancing Speed-to-Market and Supply Chain Resilience
The Mexicali investment reinforces Disruptive Packaging’s speed-to-market capabilities. Regional production allows the company to respond quickly to shifting demand and seasonal peaks.
Because the facility operates under the USMCA framework, customers benefit from tariff-free trade across North America. That structure supports pricing stability and long-term planning.
Mark Delafosse, director of global solutions sales, said the company designed the plant to strengthen resilience. He noted that localized manufacturing reduces freight distances and improves efficiency.
“Our Mexicali facility will greatly enhance our speed-to-market capabilities,” Delafosse said. He emphasized that the company now serves key markets within North American borders while introducing commercially viable, sustainable alternatives.
Industry observers continue to highlight supply chain resilience as a critical factor for food and protein producers. Therefore, packaging partners that deliver reliability and sustainability gain strategic importance.
Future Growth Across North America
Disruptive Packaging leaders view the Mexicali opening as a launchpad for broader regional expansion. The company continues to invest in innovation, capacity, and customer partnerships.
Penn said the investment reaffirms the company’s commitment to operational excellence in Mexico and across North America. He stressed that quality, sustainability, and innovation remain central to future growth.
As demand for environmentally responsible packaging rises, Disruptive Packaging aims to scale production while maintaining closed-loop recycling standards. The company expects the Mexicali facility to play a pivotal role in that strategy.
Founded as a global packaging manufacturer and inventor of URTHCOR®, Disruptive Packaging positions itself as a disruptor in a market long dominated by fiber-based and foam materials. With the new facility online, the company now advances its mission with greater speed, scale and regional strength.