Tetra Pak has introduced an innovative solution in its aseptic beverage cartons where the traditional aluminum foil layer is replaced with a new paper-based barrier. This innovation increases the paper content in beverage cartons to approximately 80% and, when combined with plant-based polymers, increases the traceable renewable content of a carton up to 92% – cutting the carbon footprint by up to 43%.

By simplifying the material structure from three to two main materials: paper and polymers, further benefits are anticipated for recycling infrastructure. These include maximizing the recovery of paper content during the recycling process of carton packages and delivering high-quality fiber and non-fiber fractions.

To accelerate the development of this innovative aseptic packaging material, Tetra Pak is investing €60 million in a new paper-based barrier pilot plant in Lund, Sweden. This facility will also provide its customers with valuable insights into the new solution across the entire manufacturing journey – from barrier creation to packaging material and filled package production.

The paper-based barrier pilot plant will be located in Lund, selected for its strong ties to existing research and material development, close collaboration with Lund University, and access to advanced testing capabilities at the MAX IV Laboratory in Lund.

Joakim Tuvesson, vice president materials & package at Tetra Pak said, “By expanding our facilities and strengthening strategic partnerships, we aim to make our innovative paper-based barrier accessible to more customers, accelerating their transition to sustainable packaging materials. We look forward to starting production and welcoming first customers to the new pilot plant in the first quarter of 2027.”

This investment forms part of Tetra Pak’s ongoing commitment to invest approximately €100 million annually through to 2030 in the development of sustainable packaging solutions. The world’s first aseptic beverage carton with a paper-based barrier was launched in 2023 with a Portuguese dairy producer, setting a new benchmark for sustainable packaging and winning Tetra Pak the Resource Efficiency award at the Sustainable Packaging News Awards 2024.