Tetra Pak Introduces Paper-Based Barrier Technology for Juice Packaging

Tetra Pak, in partnership with García Carrión, has introduced the first-ever use of its paper-based barrier technology in juice packaging. This major development in sustainable food packaging aims to cut dependence on fossil-based materials. The new packaging is now being introduced across several markets.

World-first aseptic carton with a paper-based barrier for juice

Tetra Pak and leading Spanish beverage producer García Carrión have launched the Tetra Brik® Aseptic 200 ml Slim Leaf carton with a paper-based barrier for juice, sold under the Don Simón brand. This is the world’s first single-serve juice carton to use this technology and the first of its kind available in Spain.

The carton is made with up to 80% paper, strengthening its sustainability profile. When combined with plant-based polymers used in the coating layers, the total renewable content reaches 92%. According to the Carbon Trust, this results in a 43% lower carbon footprint compared with conventional aseptic cartons that use aluminium foil and fossil-based polymers.

“We are proud to lead sustainable packaging innovation in the juice category. For more than 135 years, García Carrión has focused on responsible innovation and respect for the environment,” said Don José García Carrión, President of García Carrión. Fala Corujo, Vice President of García Carrión, added that the new packaging supports the company’s goal of reducing environmental impact while continuing to deliver high-quality products.

For García Carrión, this launch marks a new industrial application of its 360° Sustainability Strategy, which was recognised with the Factories of the Future Award 2024 for Excellence in Sustainability and Circular Economy.

Tatiana Liceti, Executive Vice President, Packaging Solutions at Tetra Pak, said: “This launch is an important step in our journey towards fully renewable and recyclable packaging. By working closely with our customers, we are demonstrating that sustainable innovation can be scaled across markets and product categories, without compromising packaging performance or quality.”

What is the paper-based barrier?

Tetra Pak’s paper-based barrier is a breakthrough in aseptic carton design. It replaces the traditional aluminium foil layer with a renewable, paper-based alternative, helping shift away from fossil-based materials and lowering the package’s carbon footprint. Along with the other packaging layers, the paper-based barrier protects against oxygen, light, moisture and bacteria, ensuring food safety and shelf life comparable to cartons that use aluminium foil.

Where recycling infrastructure is available, aseptic cartons with the paper-based barrier can be collected, sorted and recycled at scale. The new barrier is also expected to improve recycling efficiency by increasing paper fibre recovery while maintaining high-quality fibre and non-fibre materials.

This technology supports Tetra Pak’s wider ambition to develop the world’s most sustainable food package—one that is paper-based, made entirely from responsibly sourced renewable or recycled materials, has the lowest possible carbon footprint, and is fully recyclable.

Tetra Pak first introduced its aseptic beverage carton with a paper-based barrier in collaboration with a dairy company in Portugal in 2023. The innovation was recognised at the Sustainable Packaging News Awards 2024, where it received the “Resource Efficiency” award.

Source: tetrapak.com