Tetra Pak transforms used beverage cartons into transport crates

In an innovative step towards a circular economy and as a result of close collaboration, Tetra Pak and Schoeller Allibert have launched a new transport crate made of polyAl from used beverage cartons.

Schoeller Allibert is a leading global manufacturer of returnable transport packaging solutions. By integrating up to 50% polyAl from used beverage cartons with raw materials from other recycled streams (without using any virgin materials), Schoeller Allibert has developed warehouse crates and other reusable logistics packaging that meet high industry standards for performance and durability, offering a more sustainable and cost-competitive alternative to conventional offerings.

The crates are currently undergoing rigorous quality and durability field tests. Once validated, Tetra Pak will gradually replace over 50,000 crates used at its global spare parts distribution centre in Lund, Sweden.

Beyond Tetra Pak, Schoeller Allibert is already engaging with other potential customers to adopt this material for their returnable transport packaging needs.

Kinga Sieradzon, Vice President Sustainability Operations, Tetra Pak, said: Aseptic cartons are crucial to providing food access and safe nutrition. And, at Tetra Pak, we know how important it is to also consider its end of life, keeping valuable materials in use.

Over the years, we have been exploring viable applications for the recycled material polyAl, and we are pleased to see that our collaboration with Schoeller Allibert has resulted in a robust, competitive industrial product. We will continue to work with recyclers around the world to develop commercially viable products and expand their end market, thereby helping to reduce virgin plastic use and driving progress towards a circular economy.

Aseptic beverage cartons are made up of, on average, 70% paperboard made from wood sourced from FSC™ certified forests and other controlled resources. The remainder is made up of an ultra-thin aluminium layer that shields food from light and oxygen and thin layers of polymers that block moisture and hold the layers together. Such multi-layered structures enable the package to protect the food inside and allow for distribution and storage at room temperature.

Britta Wyss Bisang, VP Sustainability and Strategic MarCom, Schoeller Allibert, said: For our customers, making supply chains more sustainable is a key priority, and material innovation is one of the main drivers in making that happen. That’s why we are heavily investing in new ways to reduce the use of virgin plastic and use recycled materials such as polyAl. This project demonstrates how advanced recycling solutions can turn waste into durable, reusable packaging that supports circular logistics and thereby the transition to a circular economy.

In recycling, the fibres in the cartons are extracted at paper mills. The remaining mixture of polymers and aluminium can be turned into polyAl pellets for products such as pallets, crates, logistics packaging and outdoor furniture.

This article was originally published by Tetra Pak.