April 29, 2025
Could a new paper-based cap point to the future? Here’s how the shift towards paper-based packaging is inspiring innovation.
New regulations, increasing consumer expectations, and the global push to reduce plastic use are reshaping packaging as we know it.1 The future belongs to renewable, recyclable materials – and paper is leading the way.
“We’re on a journey to deliver the world’s most sustainable food package,” says Aldo Fontana, Global Product Manager at Tetra Pak. “That means a carton fully made from renewable or recycled materials, responsibly sourced to reduce environmental impact. It also means designing for circularity and ensuring a package is easily recyclable and offers a high yield of recycled materials.”
Now, it’s time for the next step in that journey: testing an industry-first paper-based cap.
The shift toward paperisation is transforming the industry. Manufacturers are replacing plastic components with fibre-based solutions to increase the share of renewable materials and promote recyclability. Consumer expectations are rising, too – 31% of consumers say they would recycle cartons more if they were made entirely of paperboard, while 21% want packaging made only from renewable materials.
“Consumers now see cartons as the most environmentally sound beverage packaging2,” Aldo explains. “The paper-based cap builds on this momentum and supports our goal of maximising paper content in our solutions – while maintaining functionality and making the transition smooth for both food and beverage producers and consumers.”
“Consumers see cartons as the most environmentally sound beverage packaging. The paper-based cap builds on this momentum and supports our goal of maximising paper content in our solutions.”
Engineering the paper-based cap
For years, Tetra Pak has been investing in research and development to increase the share of paper-based content in carton packages – moving away from fossil-based plastic and working toward a simplified material structure.
Most recently, a paper-based barrier was introduced to replace the aluminium foil layer in aseptic cartons, which can increase the share of paper content to approximately 80%. When combined with plant-based polymers derived from sugarcane, this can help reduce the carbon footprint of aseptic food packaging by up to 33%.3
Developing a paper-based cap can take the number even higher – but it’s an ambitious goal that requires carefully balancing package integrity, production line compatibility and consumer functionality.
“Creating a cap from paper isn’t as simple as swapping materials,” explains Pietro Martini, Manager Solutions Scouting & Early Innovation at Tetra Pak. “It requires an entirely new approach to engineering, material science and production technology. That’s why it’s so important to test our innovations so we can see what consumers think of it and get data on how it performs before we move toward industrialisation and full-scale production.”
The test will provide valuable data on how the cap performs in real-world conditions: “This is not just a packaging tweak – it’s a vertical innovation. Paper is traditionally used for packaging, not closures,” says Pietro. “Adapting it for a cap changes everything, from raw material sourcing to supply chain adaptation, manufacturing and consumer interaction.”
“This is not just a packaging tweak – it’s a vertical innovation. Paper is traditionally used for packaging, not closures.”
Collaborating on a real-world consumer test
There’s no proper test without collective effort – and long-time customer Aneto from Spain is now introducing a first pilot batch of family packages. Aneto has consistently pushed boundaries to align packaging choices and values, so it made perfect sense for the company to put the industry-first cap on shelf for a commercial consumer test in Spain.
In 2021, Aneto introduced sugarcane-based polymers in both caps and packaging material coatings, increasing the share of renewable materials in their products. Testing a paper-based cap was the next natural step to becoming less reliant on fossil-based resources – and it has a real impact.
By replacing the plastic cap with a paper-based alternative, the paper content in the package increases by 3%, now representing approximately 73% of the total package share by weight. Together with plant-based polymers used in the packaging material coatings and the neck of the opening, the overall share of renewable content in the package is 87%.4 That means consumers get a high share of renewable materials in their packaging, making it easier to make more sustainable choices without compromising on convenience.
"Sustainability isn’t just a commitment for us – it’s a key part of our DNA and brand identity,” says Joaquim Jiménez Santamaria, CEO & Managing Director at Aneto Natural. “We were among the first brands in Spain to use plant-based packaging, and we’re always looking for ways to reduce our environmental impact.”
For the test, Aneto’s ecological vegetable broth was chosen. This product has steady, year-round demand, making it an ideal choice for a controlled test production run.
“We’re always open to testing innovations that align with our values,” Joaquim explains. “We want to lead in sustainability while giving our customers the best possible experience.”
What will consumers think of the new cap?
One of the biggest challenges in developing new packaging innovations is ensuring they work without causing disruption.
“The test gives us an opportunity to see how consumers react,” says Aldo. “And to make sure that what we’ve developed performs just as well as traditional caps.”
The cap needs to be able to handle moisture, temperature shifts, and transportation stress while maintaining product quality.
"One of our top priorities is ensuring that the cap meets the same performance standards as plastic caps," says Pietro. "It has to be easy to open, resealable, and durable."
"One of our top priorities is ensuring that the cap meets the same performance standards as plastic caps. It has to be easy to open, resealable, and durable."
To ensure this, the cap has been tested according to Tetra Pak standards and protocols to evaluate package integrity, material resilience, and recyclability.
Because as Pietro points out, this isn’t just a little packaging tweak – it’s a fundamental shift in closure technology.
“As with any new innovation, production needs to scale over time,” says Pietro. “As we refine the process and optimise manufacturing, the technology will become more accessible across the industry.”
Paper holds the potential for an industry shift
The paper-based cap is part of a bigger movement – one that’s rapidly gaining momentum.
“The trend toward paper-based packaging is accelerating,” says Aldo. “Every step makes a difference and helps move us closer to a low-carbon, fully renewable package. We sell more than 16 billion carton packages with caps in the EU alone. So, imagine the impact on plastic reduction if even a fraction of these transitioned to paper-based caps.”
“We sell more than 16 billion carton packages with caps in the EU alone. So, imagine the impact on plastic reduction if even a fraction of these transitioned to paper-based caps.”
For Aneto, this collaboration reinforces their leadership in sustainable packaging – a journey they’ve been on for years.
"We’re proud to be part of this," says Joaquim. "For us, it’s about more than just innovation – it’s about staying true to our values and showing what’s possible."
Aldo, Pietro and the rest of the team will keep rethinking materials – and rethinking the entire lifecycle of packaging.
“Our focus is on creating solutions that are made solely from responsibly sourced renewable or recycled materials, and fully recyclable,” says Aldo.
The journey towards the world’s most sustainable package continues. And while the cap might be small, its impact could turn out to be anything but.
Want to see the different ways we work with our materials and the latest paper-based innovation in aseptic packaging? Find out more about the anatomy of our carton packages.
1 Tetra Pak® Paperisation Trend Report 2024.
2 Tetra Pak® Sustainable Packaging Research 2023 comprising more than 14,500 interviews online in 29 countries
3 Carbon Trust-verified Tetra Pak ‘Carton CO2 Calculator’ model version 9 (valid from 2023-01-01). Scope: cradle-to-grave measurement of a Tetra Brik® Aseptic 200 Slim Leaf carton with plant-based polymers in coating and paper-based barrier compared to a standard Tetra Brik® Aseptic 200 Slim Leaf package. Geography: EU Industry data.
4 The percentage of the paper content increase and the share of renewable materials is based on the actual material weight. To calculate the plant-based share of materials in a package, we sum the weight of the paperboard and the plant-based plastic and divide it by the total weight of the materials in the package.