Tetra Pak, Sterilgarda Alimenti launch 1L carton with paper-based barrier, cutting carbon footprint by 50%

SWITZERLAND – Tetra Pak and Italian dairy company Sterilgarda Alimenti have unveiled the first 1 litre aseptic carton featuring a paper-based barrier, increasing renewable content to 90 percent when combined with plant-based polymers, while reducing carbon footprint by up to 50 percent as verified by the Carbon Trust.

Designed for ambient distribution, Tetra Pak says the carton supports shelf life and performance comparable to traditional aseptic packaging with an aluminium foil barrier. 

The paper-based barrier reduces the carton’s material content from three to two main materials: paper and polymers. 

The increased paper content can support recycling infrastructure by improving material recovery and quality, while maintaining the strength and rigidity required to protect aseptic products throughout their lifecycle.

From Portion Pack to 1 Litre

Tetra Pak’s aseptic beverage carton with a paper-based barrier was first launched in 2023 in a portion package format on flexible lines. 

The technology was later expanded to high-speed lines. Scaling to a 1 litre carton is significant because the dairy industry’s core volume format requires high-speed filling lines, reliable shelf life, and consistent seal integrity. 

If the paper-based barrier performs on 1 litre cartons, it can replace aluminium foil across the majority of Tetra Pak’s installed base.

Investment in Sustainable Packaging

Tetra Pak has committed to investing approximately €100 million (approximately US$108 million) annually through to 2030 in the development of sustainable packaging solutions, including packages with simplified material structures and increased renewable content. 

At the start of the year, Tetra Pak invested €60 million (approximately US$65 million) into a pilot plant for its paper-based barrier technologies in Lund, Sweden, which is expected to unlock 80 percent paper content and 92 percent renewable content in a single aseptic carton.

Industry-Wide Carbon Reduction

Pro Carton announced that the carton packaging industry has achieved an 8 percent reduction in cradle-to-gate fossil carbon emissions since 2021. 

Research conducted by the Research Institutes of Sweden (RISE) and independently verified by Institut für Energie- und Umweltforschung (ifeu) in Germany confirms the annual cradle-to-gate fossil carbon footprint dropped from 929 kg CO₂ equivalent to 854 kg CO₂ equivalent per tonne.

When Paper Replaces Aluminium

Aluminium foil has been the gold standard for aseptic barrier protection for decades. But it is also the least renewable component in a carton. 

Tetra Pak’s paper-based barrier replaces it with wood fiber, renewable, recyclable, and responsible for a 50 percent carbon footprint reduction. 

For dairy brands counting down to 2030, that is not just a packaging upgrade; it is a compliance strategy.

Subscribe to our email newsletters that provide busy executives like you with the latest news insights and trends from Africa and the World. SUBSCRIBE HERE