SIG helps transition to aseptic cartons with world-first aluminium-free coating

SIG has launched the first 1-litre aseptic carton packs made of SIG Terra Alu-free + Full barrier packaging material, which are now available on shelves.

It is the world’s first full barrier packaging material for aseptic cartons without an aluminium layer, according to the company.

Following the success of this packaging material innovation in the field of single-serve aseptic cartons, SIG is now expanding the alu-free option into the juice category and a multi-serve format for the first time.

In a first step, ALDI will offer grape juice under its own brand Rio d’oro in this innovative packaging solution in parts of Germany, thereby reducing the carbon footprint of conventional multi-serve cartons by 29% (result based on an independent ISO-compliant life-cycle assessment).

The products are produced and filled at the Italian beverage and food producer Quargentan, utilising its existing SIG Midi 12 Aseptic filling machine with full performance.

SIG Terra Alu-free + Full barrier offers the same full barrier protection as standard SIG aseptic carton material and the same shelf life of up to 12 months.

The packaging material is available globally at scale and can run on existing SIG filling lines, including high-speed capabilities of up to 24,000 packs per hour for small-size cartons and 15,000 packs per hour for multi-serve formats. With only minor adjustments required to existing filling machines, this is a plug-and-play solution for brands and manufacturers seeking to make a rapid transition.

SIG noted that customers also benefit from the flexibility of the SIG filling lines. Switching between packaging material without an aluminium layer and standard packaging material is quick and easy at any time.

“At SIG, one of our goals is to increase the paper content in our aseptic cartons to at least 90% – including the closure – by 2030, allowing further reduction of carbon emissions, and creating a regenerative food packaging system. On the way there, we have developed this packaging structure that is made of more than 80% paper and reduces the number of raw materials from three to two”, said José Matthijsse, president & general manager Europe at SIG.

“This breakthrough innovation has the potential to streamline the recycling process for aseptic cartons, only requiring the separation of paperboard and polymers.”

Removing the aluminium layer from aseptic cartons – traditionally used to protect oxygen-sensitive products like juice, plant-based drinks, or flavoured milk – marks a milestone in the journey to create a regenerative food packaging system. This is a significant step in reducing the environmental impact.

The SIG Terra Alu-free + Full barrier packaging material is made from more than 80% paper and replaces the aluminium layer with an ultra-thin polymer coating that protects products against oxygen, light, moisture, and aroma loss. This cuts the number of raw materials from three to two and can lower the carbon footprint of multi-serve aseptic SIG cartons by up to 61% (result based on an independent ISO-compliant life-cycle assessment) when combined with forest-based polymers (via a certified mass-balance system) – without compromising full barrier function, shelf life or filling line performance.