How Tetra Pak Is Bringing Paper Based Barriers to Market Readiness

With an investment of 60 million euros, Tetra Pak is sending a clear signal for the future of sustainable packaging: At its site in Lund, Sweden, the company is building a state‑of‑the‑art pilot plant designed to significantly accelerate the development of paper‑based barrier technologies. The long‑term goal is to completely replace the aluminum layer currently used in aseptic carton packaging with an innovative paper‑based barrier.

The new barrier increases the paper content of the packaging to around 80 percent – and, when combined with plant‑based polymers, to as much as 92 percent renewable materials. This can reduce the packaging’s carbon footprint by up to 43 percent. By transitioning from three to just two main material streams – paper and polymers – the recyclability of the cartons also improves significantly, enabling the recovery of higher‑quality fiber fractions.

The pilot plant integrates all steps of the value chain for paper‑based barriers: from barrier formulation and material production to the filling of finished beverage cartons. This setup allows customers to gain hands‑on insights into the real‑world application of the technology. The Lund site also provides access to research expertise from Lund University and advanced testing facilities such as the MAX IV Laboratory, a European leader in synchrotron research.

“With the expansion of our infrastructure and the targeted strengthening of strategic partnerships, we aim to make our paper‑based barrier accessible to more customers and accelerate their transition to more environmentally responsible packaging materials. We look forward to starting production and welcoming our first customers to the new pilot facility in the first quarter of 2027,” says Joakim Tuvesson, Vice President Materials & Package at Tetra Pak. Tetra Pak launched the world’s first aseptic carton with a paper‑based barrier back in 2023. The new pilot plant is now intended to speed up the pathway to broad commercial adoption.

The pilot plant is part of an ambitious sustainability roadmap: By 2030, Tetra Pak plans to invest around 100 million euros annually in the development of sustainable packaging solutions. With this commitment, the company reinforces its ambition to drive the transition toward climate‑friendly materials – and sets important impulses for the entire packaging industry.