Paper-based barrier (original) (raw)

Tetra Pak chooses paper-based over polymer-based barrier

As climate change and global food systems call for low-carbon renewable materials, the carton packaging industry seeks alternatives to the aluminium foil layer that helps us to keep food safe and available everywhere. Many solutions are based on polymer barriers in the package, but we have chosen paper over plastic. Rather than increasing the carbon footprint of a package, paper allows us to reduce it. Also, when combined with plant-based polymers, the paper-based barrier increases the total renewable content of a carton to 90% – cutting the carbon footprint by one-third.1

Like all Tetra Pak paperboard, the paper used in our new barrier is sourced from FSC™-certified forests and other controlled sources. The paper-based barrier features an ultra-thin, nanometre metalised coating. Together with other layers in the packaging it protects against oxygen, light, moisture and bacteria. In this way food safety is not compromised and shelf-life is comparable to that of the aluminium foil layer.

The power of paper to protect

Scoring high on renewability, recyclability, and low carbon footprint, paperboard is now seen as the most environmentally sound material for beverage packaging2. It has a low weight, and yet it has the strength, rigidity and robustness to protect aseptic products throughout their extended life cycles. Of course, Tetra Pak has always believed in the power of paper. The high share of paperboard in our cartons today is what gives them a lower carbon footprint than other packaging options3 in the dairy and JNSD segments. And the paper-based barrier takes that even further – pushing the average of 70% paper content to approximately 80%. This alone is a major step towards our fully renewable aseptic carton package ambition.

Numbers validated by 25 million packages

An external validation of the innovative paper-based barrier involving 25 million Tetra Brik® Aseptic 200 Slim Leaf packages was carried out together with Portugese dairy producer Lactogal. The carton package was made using the paper-based barrier and plant-based polymers. With paper content increased to approximately 80% the total renewable content of the Tetra Brik® Aseptic 200 Slim Leaf reached 90%. As a result, the carbon footprint of the package was reduced by 33%.1 And critically, the safety and shelf-life of the flavoured milk product was reliably maintained.

Read press release Tetra Pak and Lactogal cut carbon footprint of aseptic cartons.

Good news for recyclers

More benefits of a paper-based barrier are expected further downstream where efficient recycling depends on the yield of paper fibre. Specifically, cartons with a higher fibre yield are more attractive to paper mills. What’s more, the paper-based barrier changes the material structure of the carton from three to just two main materials – paper and polymers. This represents an opportunity for recycling infrastructures and their efficiency.

On the path of innovation

To leverage the benefits of the paper-based barrier across our aseptic packaging portfolio we will keep up the pace of innovation. In the coming years we will bring the same high level of food protection and shelf-life to many more packaging solutions and filled products. We will upgrade sealing technologies, openings and closures too, while developing and industrialising the packaging material for widescale implementation.

1 Source: Carbon Trust™- verified Tetra Pak ‘Carton CO2 Calculator’ model version 9 (valid from 2023-01-01). Scope: cradle-to-grave measurement of a Tetra Brik® Aseptic 200 Slim Leaf carton with plant-based polymers in coating and paper-based barrier compared to a standard Tetra Brik® Aseptic 200 Slim Leaf package. Geography: EU Industry data.

2 Source: Sustainable Packaging Consumer Research 2023, Tetra Pak’s latest environmental survey, run in summer 2023 and comprising a total of 14,500 consumer interviews based on an online questionnaire in 29 markets: Germany, France, UK, Italy, Belgium, Denmark, Netherlands, Poland, Portugal, Romania, Spain, Sweden, Saudi Arabia, Turkey, South Africa, Egypt, China, India, Japan, Australia, Indonesia, Philippines, South Korea, Vietnam, Brazil, USA, Mexico, Colombia, Argentina.

3 Source: ifeu 2020, “Comparative Life Cycle Assessment of Tetra Pak® carton packages and alternative packaging systems for beverages and liquid food on the European market."