Packaging is becoming more sustainable: SIG innovates with beverage cartons without an aluminum layer

(Advertorial) SIG is the first manufacturer in the world to market a 1-liter aseptic carton package that is completely free of aluminum, yet offers full protection against oxygen and light. This represents a major breakthrough in making food packaging more sustainable.

Smaller carbon footprint

The shift to aseptic carton packaging without an aluminum layer is continuing in Europe. The innovative SIG Terra Alu-free + Full Barrier packaging, which has recently become available, is an important step in making packaging more sustainable. By omitting the aluminum layer, SIG has further reduced the already low CO2 footprint of standard SIG packaging without compromising shelf life or product protection.

Following its earlier success with aseptic single-serve packaging, SIG is now applying its aluminum-free technology to larger multi-serve formats for the first time. In an initial phase, Aldi is marketing its Rio d’oro brand grape juice in this sustainable packaging in certain parts of Germany. Production and filling will take place at Quargentan in Italy, where an existing SIG Midi 12 Aseptic filling machine will be used. This will reduce CO2 emissions from traditional multi-portion carton packaging by 29%.

Ready for global rollout

The Swiss packaging manufacturer is thus launching a new generation of aseptic carton packaging, without an aluminum layer, but with the same top protection and shelf life of up to 12 months. The packaging is designed for large-scale global rollout. It can be processed without any problems on existing SIG filling lines, even at high speeds of 24,000 packages per hour for small formats and 15,000 per hour for larger packages.

Thanks to just a few minor adjustments to the machines, this innovation is a true plug-and-play solution for brands and manufacturers who want to quickly switch to more sustainable packaging. What’s more, customers retain the familiar flexibility of SIG filling lines: switching between packaging with or without an aluminum layer is quick and easy.

“At SIG, we want to increase the paper content in our aseptic packaging – including the cap – to at least 90% by 2030. This will further reduce CO₂ emissions and help us build a regenerative packaging system,” says José Matthijsse, President & General Manager Europe at SIG. “This new packaging already consists of more than 80% paper and reduces the number of raw materials from three to two. This also simplifies the recycling process: only paper and plastic need to be separated.”

Pioneer in aluminum-free innovations

Removing the aluminum layer from aseptic cartons—traditionally crucial for protecting oxygen-sensitive products such as juices, plant-based drinks, or flavored milk—represents a major breakthrough in making food packaging more sustainable.

The new SIG Terra Alu-free + Full Barrier packaging consists of more than 80% paper. It has an ultra-thin polymer layer instead of aluminum, which offers excellent protection against oxygen, light, moisture, and aroma loss. This guarantees product quality and shelf life, while significantly reducing the environmental impact. CO₂ emissions can be reduced by up to 61%, especially in combination with wood-based polymers.

In 2010, SIG was the first to introduce aluminum-free packaging for aseptic cartons, specifically for neutral dairy drinks. Since then, more than 4 billion of these packages have been sold worldwide. Building on this experience, SIG continues to expand its sustainable SIG Terra range, with the ambition of making packaging increasingly lighter, simpler, and more environmentally friendly.

More info: www.sig.biz