Tetra Pak debuts first-ever paper cap on Aneto Broth

SPAIN – Tetra Pak has taken a significant step in the paperization movement with the launch of its first paper-based cap, now being tested on cartons of Aneto’s vegetable broth.

The innovation pushes the boundaries of sustainable packaging, resulting in a carton that comprises 73% paper by weight and, when including plant-based polymers used in coatings and the opening mechanism, boasts 87% renewable content.

The initiative aligns with a growing industry trend toward increasing the use of renewable, fibre-based materials in packaging.

Tetra Pak has been vocal about its commitment to moving away from fossil-based plastics, simplifying material structures, and maximizing paper content in its cartons.

“We’re on a journey to deliver the world’s most sustainable food package,” says Aldo Fontana, Global Product Manager at Tetra Pak.

“That means a carton fully made from renewable or recycled materials, responsibly sourced to reduce environmental impact. It also means designing for circularity—ensuring packaging is easy to recycle and offers a high yield of recovered materials.”

Aneto, an early adopter of sustainable packaging, had previously switched to sugarcane-based polymers for its caps and coatings. Its strong year-round demand made it an ideal candidate for the pilot test.

The trial involves a limited run of family-sized cartons equipped with the new paper cap in the Spanish market.

While Tetra Pak has already evaluated the cap’s performance in terms of structural integrity, recyclability, and durability under laboratory conditions, the field test will provide critical insights into how it performs in real-world scenarios—exposed to moisture, temperature changes, and transit stress, all while maintaining product quality.

“Creating a cap from paper isn’t just about swapping materials,” explains Pietro Martini, Manager of Solutions Scouting & Early Innovation.

“It demands an entirely new approach to engineering, material science, and production technology. This is a vertical innovation—paper is traditionally used for packaging, not closures. Transforming it into a functional cap affects everything from material sourcing to manufacturing and end-user interaction.”

Tetra Pak emphasizes that the new paper-based cap must meet or exceed the functionality of its plastic counterparts.

It must be easy to open and reseal, durable, and compatible with existing filling and sealing equipment.

As with any emerging technology, scaling up production will take time, but Tetra Pak is confident the solution will become increasingly viable as manufacturing processes are refined.

“The test allows us to see how consumers react,” adds Aldo. “It’s crucial to ensure that what we’ve developed performs just as well in terms of consumer experience and convenience.”

For Aneto, the initiative reflects its ongoing commitment to sustainability. “This isn’t just a partnership—it’s an evolution of our brand’s values,” says Joaquim Jiménez Santamaria, CEO and Managing Director at Aneto Natural.

“We were one of the first brands in Spain to use plant-based packaging. We welcome innovations like this that help us reduce environmental impact while delivering the quality our customers expect.”

Tetra Pak points to consumer data supporting its direction: 21% of shoppers express a preference for packaging made solely from renewable materials, while 31% say they would be more likely to recycle cartons if they were entirely made from paperboard.

“Consumers increasingly perceive cartons as the most environmentally responsible beverage packaging,” Aldo notes.

“This paper-based cap builds on that trust and supports our vision of a fully paper-based, low-carbon package that functions seamlessly for both brands and consumers.”

The development follows other innovations by Tetra Pak, such as its collaboration with Nissha Metallizing Solutions to replace the aluminum foil layer in aseptic beverage cartons with a paper-based barrier made from FSC-certified sources.

This breakthrough could raise the paper content in such cartons to 80%. When combined with sugarcane-based polymers, the result is a potential carbon footprint reduction of up to 33%.

With the introduction of the paper cap, Tetra Pak expects to push this figure even higher, without compromising the package’s performance, compatibility with existing filling lines, or consumer usability.

“The trend toward paper-based packaging is gaining momentum,” Aldo concludes. “Every step we take brings us closer to our goal of a fully renewable, low-carbon package. We sell over 16 billion carton packages with caps annually in the EU alone.

“Even a modest shift to paper-based caps could significantly reduce plastic usage and accelerate sustainable change across the industry.”

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