Key Development 

SIG Combibloc Group, a global leader in aseptic packaging solutions, has unveiled the world’s first 1-litre aseptic carton aluminium-free, using its breakthrough Terra alu-free full-barrier material. This innovation eliminates aluminium while maintaining full product protection, marking a major step toward sustainable packaging. German retailer ALDI is the first to adopt the format, offering its Rio d’oro grape juice in the new pack.

Paper-Based Design with Strong Barrier Protection

The new carton is made from over 80% paper and replaces the conventional aluminium layer with an ultra-thin polymer barrier that effectively protects contents from oxygen, light, and moisture. The solution maintains a 12-month shelf life while reducing raw materials from three to two. According to SIG, it can cut the carbon footprint of multi-serve aseptic cartons by up to 61% when paired with forest-based polymers.  Production and filling are currently underway at Quargentan, an Italian food and beverage company, using existing SIG Midi 12 Aseptic lines, demonstrating full compatibility with current equipment. The alu-free solution also supports high-speed filling, delivering up to 24,000 packs per hour for small cartons and 15,000 for larger formats.

Global Rollout and Carbon Savings

ALDI’s transition to the aluminium-free carton reduces its packaging-related carbon footprint by 29% compared to traditional multi-serve cartons. Introduced in May 2025, SIG plans to expand the Terra alu-free material across its entire range of aseptic cartons for beverage and dairy categories worldwide. This launch aligns with a growing industry push for eco-friendly packaging, alongside similar initiatives by Elopak, OHPC, and Dow, which are also incorporating renewable and recycled materials.

Redefining Sustainability in Packaging

By eliminating aluminium without compromising safety, quality, or convenience, SIG Combibloc Group reinforces its position as an innovator in sustainable aseptic packaging, setting a new benchmark for the global food and beverage industry.

Source: Foodtech Network