What is the definition of aseptic carton packaging?
Aseptic carton packaging allows for distribution in ambient conditions. This means that food for ambient distribution is food that, after being packed, can be safely stored at room temperature without the occurrence of microbial growth.
Aseptic technology can help you preserve the taste, appearance, textures and product quality of your liquid food or beverage for an extended period of time without the need for preservatives or refrigeration. The combination of our aseptic processing and packaging solutions makes distribution very cost-efficient, allowing our customers to expand their reach globally.
What factors are important to consider when it comes to filling products in aseptic carton packaging?
Your aseptic technology must ensure that both the product and packaging materials are free of harmful bacteria while being packaged – everything in the production chain must be commercially sterile. This includes all food and packaging materials, all machinery, and the environment in which the packaging takes place.
Which products are suitable, or unsuitable, for aseptic carton packaging?
The aseptic packaging process is used for various food products and beverages, including but not limited to milk, juices, tomatoes, soups, broths, soya and other plant-based beverages, wines, and teas and coffee drinks.
Products that are not suitable include chilled yoghurt, which contains live and healthy bacteria cultures. However, yoghurt, which doesn´t include live bacteria cultures, is available in ambient packaging in some markets, although this causes the product to lose some of its inherent benefits due to the tougher processing required.
How does aseptic packaging differ from packages for chilled products?
Aseptic packaging involves packing the product in a sterile environment into a sterile packaging material, which differs from the process involved in chilled packaging.
With chilled or cold chain packages, however, the product is not commercially sterile – for example, those that include live bacteria – and therefore must be kept refrigerated below 8°C.
The main difference between aseptic and chilled packaging material is that the former, within the layered materials, includes a barrier layer – typically aluminium - to protect against light and oxygen, keeping perishable food safe without refrigeration for months.
How is aseptic carton packaging created?
Aseptic carton packaging is created with paperboard, which provides stability and strength, as well as a thin layer of aluminium foil to keep out air and light, to maintain product quality. Additionally, very thin layers of polyethylene are used to protect against outside moisture, help the paperboard bond with the aluminium and protect the paperboard, and prevent moisture or the product from getting out. Plastic is used to make caps, closures, and straws, although these are also available in plant-based material.
Are there any benefits specific to aseptic products packed on aseptic carton packages, and how do they help producers?
Aseptic packaging solutions ensure products have a long shelf life without the need for refrigeration or preservatives. Aseptic carton packaging without the need for refrigerated transport or an extended cold chain, allows for perishable food and beverages to be transported longer distances through differing climates, as well as maintaining their quality for a longer period of time compared to chilled products.
How is packaging material sterilised prior to filling?
There are two main methods of sterilisation. One way is for the packaging material to be sterilised both inside and out in a peroxide bath.
A second option is using eBeam technology for sterilising the inner and outer parts of the packaging material throughout the production process. Electron emissions guarantee an equivalent sterilisation performance to that of hydrogen peroxide systems, and is the latest innovation on our Tetra Pak® E3 filling machine platform fillers.
What solutions are available for the transportation of aseptic packages?
Tetra Pak offers several different secondary packaging solutions that meet various needs in different conditions. These secondary packaging solutions are transported in pallets, where the height and pallet pattern depends on the secondary packaging solution chosen, as well as constraints in the distribution environment.
What formats of aseptic packaging exist to serve different products?
Aseptic packaging typically comes in a variety of shapes, sizes, and formats, suitable for different consumption occasions – from portion packs for on-the-go consumption to packaging designed for home pouring.
We currently have seven different formats in our aseptic packaging family, all of which come in a wide variety of sizes, with numerous openings options, and suitable for a broad range of product categories.
What future developments and innovations are expected with aseptic carton packaging?
Our ambition is to deliver the world's most sustainable paper-based food and beverage package1. With our four focus areas we aim to enable the use of renewable materials, maximise the value of recycled material, minimise littering and make sure the package of the future is designed for recycling.
In this latter area, we’re investing in research and development to find renewable alternatives that can help us replace the aluminium foil layer in our aseptic cartons, shift away from virgin, fossil-based materials, and increase the share of paper-based content in our carton packages. For example, in 2023 we launched the Tetra Brik® Aseptic 200 Slim Leaf carton with a paper-based barrier, a first within the food carton packaging industry, which, together with the maximised use of plant-based materials in the package, achieved a remarkable 90% renewable content.
1 A carton package made of renewable or recycled materials, which are responsibly sourced, therefore helping protect and restore our planet’s climate, resources and biodiversity; contributing towards low carbon production and distribution; convenient and safe, therefore helping to enable a resilient food system; fully recyclable.