Maya Ellison
Tetra Pak is a hot topic in the eco-space. It is a packaging material made from multiple layers of paperboard, plastic, and aluminium. Tetra Pak cartons are primarily paper-based, with an average carton consisting of about 70% paperboard, 25% plastic, and 5% aluminium. While Tetra Pak cartons are technically recyclable, the presence of plastic and aluminium makes the recycling process more complex, and they are often not accepted by recycling programs. Tetra Pak cartons have a lower carbon footprint during production compared to other packaging materials, but other factors such as transportation, recycling, and reuse also play a role in their environmental impact.
| Characteristics | Values |
|---|---|
| Composition | 70% paperboard, 25% plastic, 5% aluminium |
| Recyclability | Recyclable, but only 26% is recycled globally. |
| Environmental impact | Requires less energy to produce than other packaging, has a lower carbon footprint, and is easier to transport. |
| Food preservation | Provides protection from light, air, and microorganisms, extending the shelf life of perishable food |
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What You'll Learn
Tetra Pak cartons are made from 70% paperboard
Tetra Pak cartons are primarily paper-based, with multiple layers that keep light, air, and microorganisms out. This helps to extend the shelf life of perishable foods and reduce food waste. The cartons are also lightweight and stable, supporting low-carbon, circular food and beverage production.
The paperboard provides structure and protection to the cartons, while the plastic components, such as polymers, protect against outside moisture and enable the paperboard to stick to the aluminium foil. Plastic is also used for caps, closures, and straws. In recent years, Tetra Pak has introduced caps made from plant-based polymers and certified recycled polymers, increasing the circularity of its packages.
Aluminium, which makes up a very thin layer in the cartons, provides vital protection from oxygen and light. This layer is essential for keeping perishable food safe without refrigeration for months. Tetra Pak is working towards developing an aseptic package that uses an alternative material for its barrier layer to further reduce the use of aluminium.
While Tetra Pak cartons are recyclable, the process is complex due to the multiple materials involved. The paper fibres can be separated from the PolyAl (polyethylene and aluminium) through secondary recycling, and the paper can be incorporated into new paper products. However, the cartons are usually downcycled into building materials rather than being reused for the same purpose.
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25% of the material is plastic
Tetra Pak cartons are made of about 70% paperboard, leaving 25% of the material as plastic. The remaining 5% is aluminium.
The cartons are primarily paper-based, with paperboard sourced responsibly from renewable resources. Paperboard is used to support low-carbon, circular food and beverage production.
Plastic is used to make caps, closures, and straws. In 2011, Tetra Pak launched the industry's first caps made from plant-based polymers. In 2020, the company introduced certified recycled polymers in its carton packages, increasing the circularity of its packages.
The use of plastic in Tetra Pak cartons is a concern for some, with only around 26% of Tetra Pak recycled globally. When Tetra Pak is recycled, it is not a closed cycle, and the material is usually used to make building materials. However, Tetra Pak packaging requires significantly less energy to produce than other packaging, and it is easier to transport due to its lightweight and regular shape.
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5% of the carton is aluminium
Tetra Pak cartons are primarily made from paperboard, with more than 70% of the carton consisting of paperboard by weight. However, other materials are also used in the construction of these cartons, including polymers, plastic, and aluminium.
Aluminium makes up approximately 5% of a Tetra Pak carton. This small but crucial amount of aluminium is included in aseptic cartons to provide vital protection from oxygen and light. The thin layer of aluminium, just eight times thinner than a human hair, helps keep perishable food safe from degradation without the need for refrigeration or preservatives.
The inclusion of aluminium in Tetra Pak cartons has been a topic of discussion in the context of sustainability and recycling. Aluminium is a raw material that can have environmental implications. To address this, Tetra Pak has implemented initiatives for responsible aluminium sourcing. They have co-founded the Aluminium Stewardship Initiative (ASI), which aims to mitigate the environmental and social impacts associated with aluminium production and use.
Additionally, Tetra Pak has been working on developing alternative materials to replace the aluminium foil layer in their aseptic packages. In 2020, they conducted a 15-month commercial technology validation of a polymer-based barrier as a substitute. This was followed by a consumer test of an aseptic carton package with a paper-based barrier in 2022. In 2023, they introduced the Tetra Brik® Aseptic 200 Slim Leaf carton, which achieved a remarkable 90% renewable content with its paper-based barrier.
The company's efforts to increase the share of paper-based content in their cartons, along with their collaboration with other industries to utilise recycled materials, demonstrate their commitment to sustainability and innovation in packaging solutions.
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Tetra Pak cartons are recyclable
Tetra Pak cartons are primarily made from paper-based materials, with an average carton consisting of about 70% paperboard, 25% plastic, and 5% aluminium. While the paperboard provides a renewable and sustainable base, the plastic and aluminium components offer essential protection for the carton's contents.
The recyclability of Tetra Pak cartons depends on the availability of adequate collection, sorting, and recycling systems. These cartons are technically recyclable, but the acceptance of these packages for recycling can vary across different regions. It is always advisable to check with your local municipality or recycling facility to confirm if they accept Tetra Pak cartons for recycling.
When Tetra Pak cartons are recycled, they are typically downcycled into new products. The paper fibres are separated from the plastic and aluminium components, and the paper is then incorporated into new paper products. This process has been a common practice for several decades. However, it is important to note that the plastic and aluminium components, known collectively as PolyAl, are challenging to separate without specialised equipment.
Tetra Pak has been actively working towards enhancing the sustainability of their packaging. In 2011, they introduced caps made from plant-based polymers, and in 2020, they started using certified recycled polymers in their cartons, increasing the circularity of their packaging. Additionally, Tetra Pak is committed to promoting sustainable forest management, even though they do not own or manage forests directly.
Overall, while Tetra Pak cartons are technically recyclable, the availability of recycling programs and the process of downcycling vary across regions. Tetra Pak, as a company, is taking steps to improve the sustainability of their packaging, and their cartons have a lower carbon footprint compared to other packaging solutions.
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They are usually downcycled into building materials
Tetra Pak cartons are primarily made from paper, with other components being plastic and aluminium. They are marketed as recyclable, and while this is true, they are usually downcycled into something else rather than being recycled into new Tetra Pak cartons. This is because the process of recycling Tetra Pak cartons is complex due to their multilayer structure, and the materials used to make them are not easily separated.
The most widespread recycling option for Tetra Pak cartons is secondary recycling, where materials are processed and used in applications that do not require virgin material properties. In this process, the paper fibres are separated from the PolyAl (polyethylene and aluminium) and incorporated into paper products. This has been a common process for at least the past 40 years.
Tetra Pak cartons are also recycled into eco-friendly building materials. This is particularly prevalent in India, where the recycling rate for Tetra Pak cartons was 54% in 2019. The high recycling rate in India is due to the rising market demands for low-price products. However, it should be noted that Indian cities generate around 161,000 tonnes of Municipal Solid Waste every day, which ends up in landfills.
The development of sustainable and resistant construction materials is a significant challenge in the Civil Engineering industry. Solid waste is one of the most significant components that threaten the future of the world. Technological developments, a growing population, and changes in consumption habits have resulted in an increase in solid waste. Therefore, while Tetra Pak cartons can be recycled into building materials, it is important to address the global problem of solid waste and move towards a more circular economy.
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Frequently asked questions
Tetra Pak is made of around 70% paperboard, 25% plastic, and 5% aluminium.
Yes, Tetra Pak is recyclable. However, only around 26% of Tetra Pak is recycled globally. They are usually downcycled into building materials.
Tetra Pak boxes are better than plastic when it comes to climate change (production and transportation). However, plastic wins when it comes to plastic pollution and closed-loop recycling options.
Tetra Pak provides the needed protection to perishable foods, making them available over vast distances with a longer shelf life. They are also easier to transport and save space during transportation.
