Tetra Pak equips Maeil Dairies with paper-based barrier cartons, first in Asia

SOUTH KOREA – Maeil Dairies has become the first producer in Asia to run Tetra Pak’s paper-based barrier material on a high-speed Tetra Pak® A3/Speed filling line, marking a key step in the commercial scale-up of aluminium-free aseptic cartons.

The South Korean dairy and plant-based beverage specialist is applying the solution to its Maeil Soy Milk 99.9 range, aligning packaging innovation with its broader sustainability strategy and growing consumer demand for lower-impact products.

The milestone follows Tetra Pak’s expansion of its paper-based barrier technology to the Tetra Pak® A3/Speed platform, one of the industry’s highest-output aseptic filling systems.

Capable of producing up to 24,000 packs per hour, the A3/Speed line is widely used by large beverage manufacturers seeking operational efficiency and cost competitiveness.

Originally developed to replace the aluminium foil layer traditionally used in aseptic cartons, Tetra Pak’s paper-based barrier maintains comparable food protection and shelf life while reducing reliance on fossil-based and carbon-intensive materials.

Combined with plant-based polymers derived from sugarcane, the Tetra Brik® Aseptic 200 Slim carton used for Maeil’s soy milk contains 87% renewable content and delivers a 26% lower carbon footprint, as verified by the Carbon Trust.

Importantly for converters and brand owners, the solution can be integrated into existing production infrastructure.

Current A3/Speed lines can be upgraded with a high-frequency induction-heating sealing system, enabling manufacturers to transition to the new packaging material without significant capital expenditure, an essential factor in accelerating adoption at scale.

“Scaling sustainable packaging solutions should go hand in hand with operational efficiency,” said Tatiana Liceti, Executive Vice President, Packaging Solutions at Tetra Pak.

“By bringing our paper-based barrier to high-performing Tetra Pak® A3/Speed packaging lines, we are enabling beverage producers to adopt renewable, low-carbon packaging while maintaining food protection and cost competitiveness.”

For Maeil Dairies, a leader in South Korea’s plant-based and low-sugar beverage segments, the shift reinforces its positioning as an innovation-driven brand.

“Introducing new packaging on our Soy Milk 99.9 line reflects our ongoing commitment to innovation and environmental responsibility,” said Inki Lee, Chief Operating Officer at Maeil Dairies.

The development builds on Tetra Pak’s 2023 introduction of the first aseptic carton replacing the aluminium layer with a paper-based barrier.

By simplifying the material structure from three to two main components, the design aims to improve recyclability and maximize fibre recovery in existing recycling streams.

The announcement comes amid accelerating sustainability commitments across Asia’s food and beverage sector, as manufacturers respond to tightening climate targets, extended producer responsibility (EPR) schemes and rising scrutiny over multilayer packaging waste.

As the region’s beverage market continues to expand, scalable solutions that combine renewable content, lower carbon intensity and high-speed performance are expected to shape the next phase of aseptic packaging innovation.

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