In a world-first development, Tetra Pak and Nissha Metallizing Solutions have collaborated to introduce an aseptic beverage carton featuring a paper-based barrier. Tetra Pak Oceania MD, Boris Munster, weighs in.
The new carton design pushes the paper content in Tetra Pak’s aseptic cartons to approximately 80 per cent, reducing reliance on traditional barrier materials and cutting the carbon footprint by 33 per cent, according to the collaborators. By leveraging FSC-certified paper, this development claims to offer a more renewable alternative while ensuring product protection and shelf stability comparable to conventional aseptic cartons.
“This latest innovation builds on our foundation of high renewable content,” Boris Munster, managing director of Tetra Pak Oceania, explains. “By advancing the shift toward renewable materials, we continue to set the pace for the paperisation trend in the industry.”
Tetra Pak’s collaboration with Nissha Metallizing Solutions (NMS) was driven by the shared commitment to sustainability and product innovation. According to NMS CEO Giorgio Bosso, the breakthrough aligns with the company's broader efforts to provide recyclable, renewable, and mono-material solutions.
“Our paper-based solution offers barrier properties that help the package deliver comparable shelf life and food protection as traditional aseptic cartons for liquid dairy products, such as milk,” Bosso says.
Opportunities and challenges
As with any new technology, scaling up the paper-based barrier presents challenges, particularly in ensuring that the new design meets stringent performance standards for food safety and shelf stability. Munster notes the importance of rigorous testing: “The key challenge lies in making sure that the technology meets the needs of the markets while delivering on its primary function: protecting the product inside.”
Once commercialisation is fully realised, Tetra Pak says the new cartons will offer food and beverage manufacturers an opportunity to reduce their carbon footprint while aligning with increasing consumer demand for sustainable packaging.
Impact on recyclability
The new material structure simplifies the carton’s composition by reducing the number of different layers, a move that enhances its appeal for recyclers. In Australia and New Zealand, the local recycling infrastructure — particularly saveBOARD — already processes existing aseptic cartons, positioning the region well to accommodate the paper-based barrier when introduced locally.
Munster notes: “The paper-based barrier innovation simplifies the materials used by increasing the renewable content. Our local recycling infrastructure is well-equipped to process the existing aseptic carton design, supporting the introduction of this innovation.”
This development also aligns with Tetra Pak’s commitment to driving sustainability through increased use of responsibly sourced materials, streamlined recyclability, and investment in plant-based, low-carbon alternatives.
Tetra Pak’s sustainability roadmap includes further advancements in material science, exploring options to enhance recyclability and lower the carbon footprint of its packaging portfolio. Digital technologies designed to improve traceability and support circular economy initiatives, are also in the pipeline.
As anyone involved in packaging today knows, the regulatory landscape is fast-shifting, and with sustainable packaging evolving in response. Munster says, “The regulatory landscape plays a crucial role in driving progress, with policies promoting recyclability, carbon reduction, and extended producer responsibility encouraging innovation and collaboration.”
A defining moment?
The launch of the paper-based barrier carton is a testament to the power of collaboration in driving sustainability forward. With Tetra Pak and NMS leading the charge for aseptic packaging, the industry moves closer to a future where packaging is not only functional but also environmentally responsible.
Munster says, “We are well-positioned to adapt and lead, aligning our developments with regulatory goals to create more sustainable packaging solutions.”
As the new technology gains traction, its impact on carbon emissions, recyclability, and industry-wide adoption will be closely watched, setting the stage for the next chapter in sustainable packaging innovation.
