The role of paper in securing our food systems

Environmental sustainability issues concerning the industry

Food waste, plastic littering, and greenhouse gas emissions are the 3 foremost planetary challenges the packaging industry is now expected to address⁴. From a global perspective, food waste has the greatest sustainability impact while greenhouse gas emission is the most difficult to tackle⁴. But the industry has made commitments to mitigate these issues – and taken initiatives. Meanwhile, increasingly stringent regulation continues to push the industry to do more, albeit at a slower pace in some parts of the world.

But what prevails as the real driver of change is consumer pull⁴. Producers are setting themselves ambitious goals in an attempt to meet evolving consumer awareness. Consumers are predominantly concerned about pollution, plastic waste, and global warming⁵. It’s largely understood that packaging needs to cut back on the use of plastic and do more to reduce carbon emissions.

This ties in with a significant turning point in the perception of plastic and paper packaging. Overtaking glass for the first time, carton is now perceived by consumers as the most environmentally sound packaging⁵. This is surely a key driver in the current trend towards paperisation.

How aseptic carton technology stands up in view of this

Comparative studies show that paper-based carton packages have a lower carbon footprint than plastic, metal or glass alternatives in the dairy, juice, nectars and still drinks (JNSD)⁶ segments. On average paper accounts for approximately 70% of the material in a Tetra Pak® carton. This makes carton a strong contender in the context of global warming.

When sourced from responsibly managed forests and other controlled sources, paper made from wood fibre is a truly renewable material. This makes it the sustainable choice over fossil-based materials or those made from finite resources. Additionally, the recycling of paper opens the door to a circular economy where products are either made from recycled materials or can be recycled.

But while paper is doing all the heavy lifting for the sustainability profile of the aseptic carton, plastics and aluminium are where the potential for improvement can be found. As fossil-based plastics continue to be replaced by plant-based polymers, this is a diminishing problem. And so packaging manufacturers are now turning their attention to low-carbon alternatives to the aluminium foil layer.

For some time now, aseptic packaging specialists have been asking themselves if it’s possible to create a barrier that protects food as effectively as the aluminium foil using a renewable material. And if so, which material would that be? Some of the answers may be found in polymers, but undoubtedly some lie closer to home.

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Ongoing paperisation trend in the world of packaging

From fast moving consumer goods such as washing detergent, toilet paper and shampoo, to tech products, toys and luxury goods, the packaging industry at large is converting to paper wherever it can⁷. Cardboard has been the most used material globally for several years, but its share is steadily rising^7. New paper-based solutions have been developed, carton and paper have replaced plastic in many product categories, and many plastic packages now incorporate the use of carton in some way.

Manufacturers are seeing the opportunity to increase the share of renewable materials in their packaging and to promote greater recyclability. Above all, paperisation signals their new trajectory towards sustainably sourced renewable materials and a low-carbon circular economy. And e-commerce is a big driver. Having bloomed during the pandemic, new business models are continuing to emerge, noticeably subscription based ordering and social e-commerce. In countless product categories paperisation is being escalated by e-commerce, which is also the fastest growing channel in the edible grocery category⁸.

It’s easy to see why carton suits e-commerce. Besides having an advantageous sustainability profile, it makes picking and packing faster and more efficient⁷. It performs well on the stability and robustness that is needed across multiple touch points, and its light weight helps to reduce shipping costs⁷.

Where paperisation shows most promise

Regardless of the product category, increased paper content aligns first and foremost with the shift we must make from high-carbon, fossil-based materials to low-carbon renewable materials. And it is in this perspective that packaging manufacturers are now moving towards increased renewable content, by switching to paper-based materials or simply by increasing the share of power in their packaging solutions. But even if paper’s role in making packaging sustainable is gaining ground, there is plenty of room for improvement.

Besides increasing its use of renewable materials such as paper, aseptic carton technology needs to find ways to improve recyclability. If the share of carton fibre in our packages could be increased, for example, this would increase the paper yield for paper mills, adding more value further downstream. Furthermore, if the packaging material structure could be simplified, then the carton becomes easier to recycle, demanding less of the recycling infrastructure.

The paper-based barrier

Paper-based barrier is a new material innovation that provides an alternative to the aluminium foil layer. Providing comparable protection against light and oxygen, it sets out to maximise the renewability of aseptic beverage cartons. The first technology validation of the barrier has been completed with dairy producer Lactogal in Portugal, where some 25 million packages of Tetra Brik^® Aseptic 200 Slim Leaf were involved. Plant-based polymers were used in the coating of the packaging material. As a result, the total renewable content of the package reached 90% – and CO₂ emissions were reduced by 33% in all⁹.

These results directly address the environmental concerns surrounding carbon emissions and lack of circularity. But using the paper-based barrier instead of an aluminium foil layer is expected to bring more benefits downstream at paper mills, where high paper yield promotes efficient recycling. Furthermore, paper-based barrier changes the material structure of the carton from 3 to just 2 main materials – paper and polymers. This too brings new opportunities for recycling infrastructures and their efficiency.

In simple terms, paper-based barrier can represent an answer to the question: How can we use more renewable materials to reduce carbon footprint and improved the recyclability of aseptic carton packaging?

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Returning to consumer insight

As climate change becomes more apparent people are considering packaging more carefully, consumer research¹⁰ shows us that perception is evolving:

When asked what improvements they would like to see in beverage cartons, consumers’ top choices include a carton package made only with renewable materials (21%) and where all plastic parts are replaced with plant-based plastic (19%). This connects with their attitude towards recycling, as 31% state that they would recycle carton packages more if these were made entirely from paperboard and had no plastic or aluminium. We also see that they are much more likely to buy a brand in a package they perceive to be environmentally sound, and that these products can sustain a higher price.
It’s clear that consumers know what they want, and that they are prepared to pay for what they believe in. And perhaps most telling, based on a research study comprising more than 14,500 online interviews in 29 countries, consumers now see carton as the most environmentally sound beverage packaging.

All of this helps us to understand where aseptic carton technology needs to go next. We see how the increased share of paper and the use of plant-based polymers can help us to move away from fossil-based plastics and greenhouse emissions. And that further innovation on material structure and composition is needed.

In conclusion

Paper is part of a natural segue to a low-carbon circular economy, where fully renewable packaging from sustainable sources works hand-in-hand with highly evolved recycling systems.

At Tetra Pak, we have driven development of paperboard packaging for over 70 years, and we have seen the possibilities it can offer to protect food, people and planet, time and time again. That’s why we have never stopped investing in the research and development of this life-sustaining material.

But even though society’s use of paper to protect food is deep-rooted, there is still a long journey ahead. Today we collaborate with customers, suppliers and other stakeholders more closely than ever – and we invite you to join us. Visit us to learn how you can take part in the development of more renewable and recyclable aseptic solutions.

Learn more about the paper-based barrier material innovation