The paper-based alternative to the aluminium foil layer
As the world becomes more aware of the urgent need to source packaging with low-carbon renewable materials, we continue to innovate. And while the properties of aluminium provide an excellent source of protection against oxygen and light, developing an alternative to this layer has been a key priority. The paper-based barrier represents a critical marker in our longstanding work to design beverage cartons for recycling. It simplifies the packaging material structure, reducing it from 3 to 2 main materials, and contributes to a lower carbon footprint in our cartons1.
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 is an innovative material that consists of a paper-based protective layer featuring 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 recyclability, ease of flattening for disposal, and renewability, carton packages are perceived more favourably when compared to other packaging solutions.2 They are low in weight, and yet they have 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%.4 This is an important step towards our ambition to further maximise the use of renewable materials in aseptic cartons.
1 Source: Carbon Trust-verified Tetra Pak ‘Carton CO2 Calculator’ model version 12 (valid from 2026-01-01). Scope: cradle-to-grave measurement of a Tetra Brik® Aseptic 1000 Edge LightWing™ 30 carton with plant-based polymers in coating and cap and paper-based barrier compared to the same package with aluminium foil layer and fossil-based polymers in coatings and cap. Geography: Europe.
2 Tetra Pak® Sustainable Packaging Consumer Research 2025, comprising a total of 12,500+ consumer interviews based on an online questionnaire in 25 countries.
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.”
4 Considering a Tetra Brik® Aseptic 200 Slim Leaf carton with plant-based polymers in coating and paper-based barrier