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 seen as the most environmentally sound solution for food and beverages.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%. This alone is a major step towards our fully renewable aseptic carton package ambition.
Step inside this collaborative journey
Discover the challenges behind this project and how it has been turned into reality through expert collaboration with our customer Lactogal, in Portugal. A story which has led to the launch of the Tetra Brik® Aseptic 200 Slim Leaf carton with a paper-based barrier – a first within food carton packages distributed under ambient conditions.
Step inside this collaborative journey
Discover the challenges behind this project and how it has been turned into reality through expert collaboration with our customer Lactogal, in Portugal. A story which has led to the launch of the Tetra Brik® Aseptic 200 Slim Leaf carton with a paper-based barrier – a first within food carton packages distributed under ambient conditions.
Good news for recyclers
Simplifying the material structure of the carton from 3 to just 2 main materials – paper and polymers – the paper-based barrier increases the paper content of the packaging solution. This represents an opportunity for recycling infrastructures where the quality and recovery efficiency of materials is key. Specifically, cartons with a higher paper yield are more attractive to recycling mills.
Securing our food systems in tomorrow’s low-carbon circular economy
As the global population increases and the impacts of climate change intensify, securing the future of our food systems has never been more critical. Research and results demonstrate that the paper-based barrier can pave the way towards fully renewable and recyclable packaging – essential for tomorrow’s low-carbon circular economy. If you believe in the power of paper to safeguard food and the planet, join us on this innovation journey.
Follow #ThePowerOfPaperToProtect on social media.
1 Source: Carbon Trust- verified Tetra Pak ‘Carton CO2 Calculator’ model version 11 (valid from 2025-01-01). 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 Tetra Brik® Aseptic 200 Slim Leaf package with aluminium foil layer and fossil-based polymers. Geography: EU Industry data.
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 Paper-based, with the lowest possible carbon footprint, made solely from responsibly sourced renewable or recycled materials, and fully recyclable. This means creating cartons that are fully made of renewable or recycled materials, that are responsibly sourced, thereby helping to protect and restore our planet's climate, resources and biodiversity; contributing towards low carbon production and distribution; are convenient and safe, therefore helping to enable a resilient food system; and are fully recyclable.