Tetra Pak teams up with Schoeller Allibert to launch beverage carton crates made from recycled PolyAl

SWEDEN – Packaging giant Tetra Pak and returnable transport packaging leader Schoeller Allibert have teamed up to develop an innovative crate from recycled beverage cartons.

 The new crate, made using polyAl, the non-paper component of used aseptic cartons, will debut at the Plastics Recycling Show Europe in Amsterdam, scheduled for April 1–2, 2025.

The transport crates comprise up to 50% polyAl blended with recycled materials from other streams, eliminating the need for virgin plastics.

The result is a high-performance, reusable crate that meets industry durability and efficiency standards while offering a sustainable and cost-effective alternative to traditional plastic crates.

The crates are currently undergoing rigorous field testing and are poised to become a key component in Tetra Pak’s global operations.

Once validated, the new polyal versions will be replaced with over 50,000 crates at Tetra Pak’s spare parts distribution centre in Lund, Sweden.

“We’re proud to demonstrate how advanced recycling solutions can transform waste into durable, reusable packaging that supports circular logistics,” said Britta Wyss Bisang, Vice President of Sustainability and Strategic Marketing Communications at Schoeller Allibert.

“Sustainable supply chains are essential for our customers, and reducing virgin plastic use through innovations like polyAl is a major step forward.”

Kinga Sieradzon, Vice President of Sustainability Operations at Tetra Pak, emphasized the dual mission of protecting food and the planet.

“Aseptic cartons play a vital role in food security. However, we also recognise the importance of using materials after the package’s life cycle ends. Our collaboration with Schoeller Allibert has led to a robust industrial solution that adds real value to the circular economy.”

Marie Sandin, Managing Director of Tetra Pak Sweden, added that this innovation aligns with ongoing sustainability efforts at the company’s Lund facility.

“We’ve already incorporated polyAl in our employee furniture, and this new crate initiative continues our push for recycled and sustainable materials in every aspect of our operations. Each crate uses material from approximately 200 recycled beverage cartons—an impactful way to close the loop.”

Aseptic beverage cartons comprise about 70% FSC™-certified paperboard, with the rest composed of ultra-thin layers of aluminium and polymers.

 Paper fibres are recovered during recycling, and the remaining aluminium-polymer blend is processed into polyAl pellets.

These pellets are increasingly used in durable goods such as pallets, crates, furniture, and other logistics materials.

As both companies continue to explore and scale up the use of polyAl, the new crate represents a tangible milestone in replacing single-use plastics, expanding recycled material applications, and supporting a more circular future.

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