SIG, a global leader in aseptic carton packaging, has unveiled what it claims to be the world’s first aluminium-free, full barrier aseptic carton for multi-serve formats. This commercial rollout builds on the success of SIG’s alu-free solution for single-serve cartons, over 300 million of which have been sold in China since its 2023 debut.
The new packaging material, branded SIG Terra Alu-free + Full Barrier, eliminates the aluminium layer traditionally used in aseptic cartons to protect products from light and oxygen. Instead, SIG uses a high-performance, paper-based structure that reduces carbon emissions without compromising shelf life or processing efficiency.
“At SIG, we are leading the industry transition to alu-layer-free aseptic carton packaging materials,” said Christoph Wegener, Chief Markets Officer at SIG. “With our full barrier material with no aluminum layer, we are offering a powerful differentiator and embodiment of sustainability in aseptic carton packaging, unlocking new opportunities for packaging sensitive product categories such as plant-based products, juices, and nutritional beverages.”
The new solution retains the same performance characteristics as standard aseptic cartons, ensuring shelf stability for up to 12 months. Crucially, it is compatible with existing SIG filling lines with only minor, low-cost modifications. Production speeds remain competitive, reaching up to 24,000 packs per hour on small-size lines and 15,000 packs per hour on multi-serve lines.
Aluminium typically accounts for just 5% of a conventional aseptic carton’s weight but can contribute up to 25% of its carbon footprint in full barrier structures. By removing this component, SIG claims a reduction in carbon footprint of up to 61% when paired with forest-based polymers. The simplified structure now consists of just two primary raw materials, over 80% of which is paper sourced from renewable sources.
“Sustainability is integral to our business, and we strive to create a regenerative food packaging system,” said Gavin Steiner, Chief Technology Officer at SIG. “Looking ahead, SIG plans to raise the paper content in its aseptic cartons to at least 90% including closures by 2030, with an interim target of 85% without closure this year.”
The SIG Terra Alu-free + Full Barrier packaging will be deployed across all SIG flagship carton formats, including both small and multi-serve sizes, and will support a broad spectrum of oxygen-sensitive beverages, from flavoured dairy and plant-based drinks to fruit juices and nectars.
SIG first introduced an aluminium-free aseptic carton for dairy in 2010 and has since sold over 4 billion packs without aluminium, including 300 million full-barrier variants. This latest development cements SIG’s position at the forefront of decarbonisation efforts in the beverage packaging industry.
