Ethan Clarke
Cartons are made from multiple materials, including paperboard, plastic, and aluminium. This makes them difficult to recycle because the layers are often glued together and hard to separate. Gable-top milk cartons and aseptic cartons, for example, have paper and plastic layers that recycling plants find challenging to separate. However, recycling cartons is becoming easier, with more local authorities collecting them for recycling.
| Characteristics | Values |
|---|---|
| Recyclability | Gable-top cartons (refrigerated cartons) and aseptic cartons (shelf-stable cartons) are both recyclable |
| Composition | Gable-top cartons are made of paper and plastic liner; aseptic cartons are made of paper, plastic, and aluminum liners |
| Use | Gable-top cartons are used for refrigerated food like milk, juice, and cream; aseptic cartons are used for non-refrigerated food like soup, broth, and wine |
| Environmental impact | Recycled plastic cartons are considered "vastly superior" to pulp by some sources, while others argue that reusing plastic is better for the environment than creating new waste |
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What You'll Learn
Cartons are made from 70-90% paperboard
Gable-top cartons, or refrigerated cartons, are made of paper and plastic liners. They are used to store refrigerated products like milk, juice, and cream. Aseptic cartons, or shelf-stable cartons, are made of paper, plastic, and aluminum liners and are used to store non-refrigerated goods like soup, broth, and wine. Both types of cartons are recyclable.
The cartons are sent to a Materials Recovery Facility (MRF) after being recycled, where they are sorted, baled, and sent to paper mills and recycling plants. The paper is separated from the plastic and aluminum at paper mills using a hydro pulper. The pulp is either sent straight to the mill's paper machine or dried into sheets that are used to make paperboard, tissue, and cardboard.
Paperboard is a thick paper-based material that is produced by compressing layers of paper and cardboard together. It is a durable and lightweight material that is often used for packaging and printing. Paperboard is also known as cardboard, carton board, or chipboard, and it is commonly used for items such as cereal boxes, book covers, and folding boxes.
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The carton lining is made from plastic and aluminium
The lining of cartons is made from plastic and aluminium, and it needs to be removed from the paper before the carton can be recycled. This is because the paper is mixed with water and pulped to break it down into a fibrous solution, while the plastic and aluminium are made into products like garden furniture, play mats and building materials. The plastic used is often polyethylene, which is used as a raw material for products like crates, buckets, and coffee pots. Polyethylene is also used in the caps of cartons.
Cartons with plastic and aluminium lining are common for beverages, especially those that are long-life liquids, also known as 'aseptic products'. These include dairy products, soy milk, juices, and non-carbonated waters. The aluminium layer is very thin, at only 6.5 micrometres, but it is an excellent barrier against oxygen and light, allowing these drinks to last for up to 18 months without refrigeration or preservatives.
While cartons with plastic and aluminium lining have the benefit of being recyclable, there are concerns about the potential for chemical exposure. The plastic lining may contain harmful chemicals like Bisphenol A (BPA), which can leach into the food or drink over time. This is particularly a concern for acidic foods, such as tomatoes, which can cause more of the plastic's chemicals to break down and enter the product.
To address this issue, some companies have developed 100% bio-based cartons that do not use aluminium. For example, SIG's aseptic Signature Pack uses a polyamide (PA) polymer barrier instead of aluminium. However, these bio-based cartons have a very modest market share, and there are still challenges with recycling cartons that consist of multiple layers.
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Cartons are difficult to recycle due to layers of materials
Cartons are a popular packaging choice for food and beverage products, offering advantages such as extended shelf life, efficient shipping, and preservation without refrigeration. However, their complex structure, often consisting of multiple layers of materials, poses challenges when it comes to recycling.
The typical carton, such as those used for milk or egg packaging, is primarily composed of paper or paperboard, which makes up about 70% to 90% of its material. This paper-based component is recyclable, similar to any other paper or cardboard product. However, the complexity arises from the remaining layers of the carton.
The inner lining of cartons is usually made from a combination of plastic and aluminium. This lining serves a critical function in preserving the quality and freshness of the packaged product. However, when it comes to recycling, these additional layers create a hurdle. The various materials must be separated before they can be effectively recycled.
The process of separating the paper layer from the aluminium and plastic layers is known as hydropulping. This state-of-the-art technique reduces the cellulose content to less than 5%, allowing for the efficient separation of the different materials. After hydropulping, the paper is mixed with water and pulped to create a fibrous solution that can be dried and rolled out for new products.
While the recyclability of cartons is improving, with advancements in technology and an increasing number of local authorities accepting cartons for recycling, it is still essential to be aware of the specific guidelines in your area. Some regions may have more advanced recycling facilities capable of handling complex materials, while others may have limitations. Checking local disposal guidelines is crucial to ensure cartons are properly recycled and do not end up in landfills.
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Cartons are lightweight and energy-efficient
The debate around whether cartons should be made of paper or plastic is a complex one, with environmental implications to consider. While cartons have traditionally been made of paper, with moulded paper pulp and cardboard egg cartons being the status quo since the invention of the first egg carton in 1911, some companies have switched to plastic cartons. This decision has been met with criticism, as consumers associate plastic with negative environmental impacts. However, companies like Pete & Gerry's defend their choice by arguing that their cartons are made from plastic that is already destined for landfills or the ocean, diverting it from the waste stream and giving it a new life. They also claim that the recovery rates for plastic have improved over the last decade.
On the other hand, paper cartons have their own environmental advantages. Paper is a renewable resource, with cartons being about 70% paper, and it is increasingly sourced from Forest Stewardship Council (FSC)-certified sources. The European pulp, paper, and board industry is known for its sustainable energy use, with the majority of its primary energy coming from biomass. This helps to reduce the reliance on non-renewable energy sources such as fossil-based oil, coal, or gas. Additionally, the paper industry is making efforts to improve its energy efficiency by implementing measures such as high-efficiency mechanical dewatering and combined heat and power plants to reduce energy consumption during the production process.
Cartons, whether made of paper or plastic, offer lightweight and energy-efficient packaging solutions. Being rectangular, cartons are more efficient to pack and ship, and they are also lighter than cans. Tetra Pak, a leading carton manufacturer, reports that its beverage cartons are only 4% packaging to 96% product by weight, compared to 13% packaging for steel cans. This reduced packaging contributes to the overall energy efficiency of cartons.
Furthermore, cartons are resource-efficient, conserving more resources than they use. Carton fibre, for example, can be recycled more than 25 times, and the industry is committed to reducing and replacing the use of non-renewable resources with environmentally friendly alternatives. Sheetfed inks, which integrate up to 100% renewable vegetable oils, help reduce Volatile Organic Compound (VOC) emissions. Additionally, in integrated cartonboard mills, wood by-products from the pulping process provide renewable energy in the form of electricity and steam for manufacturing, contributing to biomass energy improvements.
In conclusion, cartons, whether made of paper or plastic, offer lightweight and energy-efficient packaging options. The true environmental impact of cartons lies in their efficient design, reduced packaging, recyclability, and the industry's commitment to improving resource efficiency and reducing the use of non-renewable resources. While the choice between paper and plastic cartons is complex, the larger issue at hand is reducing the overall amount of packaging we use.
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Cartons are sorted from other recyclables and pulped
Once cartons are collected and brought to a materials recovery facility (MRF), they are separated from other recyclables. This process is called single-stream sorting, where recyclables are sorted into four categories: fibres (including cartons, newspaper, and cardboard boxes), plastic, metals, and glass. Cartons are then sorted from the rest of the fibres with the help of an artificial intelligence (AI) robot. The AI robot works best with uncrushed cartons, so it is recommended not to crush cartons before recycling them.
After the cartons are sorted, the lining materials are removed. The paper is then mixed with water and pulped for 20 minutes to break it down into a fibrous solution. This solution is then dried and rolled out into new products. The new products made from recycled cartons include tubes for hot chocolate and gravy.
The plastic and aluminium from carton linings are also recycled and made into new products. Examples of such products include garden furniture, play mats, and building materials.
Overall, the process of sorting and pulping cartons is an important step in the recycling journey. It allows for the creation of new consumer paper products and gives carton linings a new life by repurposing them into various items.
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Frequently asked questions
Cartons are made from 70-90% paperboard, which is recyclable just like any other paper or card. The carton lining is made from plastic and aluminium and needs to be removed from the paper before it can be recycled.
After being collected, cartons are sorted from other recyclables. The lining materials are removed, and the paper is mixed with water and pulped for 20 minutes to break it down into a fibrous solution.
The fibrous solution is then dried, rolled out, and made into new products. Once cartons have been recycled into rolls of new material, it can be made into new products like tubes for hot chocolate and gravy.
In most cases, the plants strip the fibre from cartons and recycle it, but they do not necessarily recycle the plastic or aluminium components.
Cartons have multiple layers of materials that are difficult to separate, which is why they have traditionally been sent to landfills. However, recycling cartons is becoming much easier, with more and more local authorities collecting them for recycling.
