In an innovative step towards a circular economy and as a result of close collaboration, Tetra Pak and Schoeller Allibert will launch a new transport crate made of polyAl from used beverage cartons at the Plastics Recycling Show in Amsterdam from 1 to 2 April 2025.
Schoeller Allibert is a leading global manufacturer of returnable transport packaging solutions. By integrating up to 50% polyAl from used beverage cartons with raw materials from other recycled streams (without using any virgin materials), Schoeller Allibert has developed warehouse crates and other reusable logistics packaging that meet high industry standards for performance and durability, offering a more sustainable and cost-competitive alternative to conventional offerings.
The crates are currently undergoing rigorous quality and durability field tests. Once validated, Tetra Pak will gradually replace over 50,000 crates used at its global spare parts distribution centre in Lund, Sweden.
Beyond Tetra Pak, Schoeller Allibert is already engaging with other potential customers to adopt this material for their returnable transport packaging needs.
Britta Wyss Bisang, VP Sustainability and Strategic MarCom, Schoeller Allibert highlighted the role of material innovation in building more efficient and sustainable supply chains: “For our customers, making supply chains more sustainable is a key priority, and material innovation is one of the main drivers in making that happen. That’s why we are heavily investing in new ways to reduce the use of virgin plastic and use recycled materials such as polyAl. This project demonstrates how advanced recycling solutions can turn waste into durable, reusable packaging that supports circular logistics and thereby the transition to a circular economy.”
Kinga Sieradzon, Vice President Sustainability Operations, Tetra Pak comments: “Aseptic cartons are crucial to providing food access and safe nutrition. And, at Tetra Pak, we know how important it is to also consider its end of life, keeping valuable materials in use.
“Over the years, we have been exploring viable applications for the recycled material polyAl, and we are pleased to see that our collaboration with Schoeller Allibert has resulted in a robust, competitive industrial product. We will continue to work with recyclers around the world to develop commercially viable products and expand their end market, thereby helping to reduce virgin plastic use and driving progress towards a circular economy.”
Marie Sandin, Managing Director of Tetra Pak Sweden, concludes: “At the Tetra Pak site in Lund, Sweden, we have actively worked over the past year to introduce sustainable and recycled materials in everything we do. For instance, we now have both indoor and outdoor furniture for our employees made from polyAl material. Our objective with this initiative, together with Schoeller Allibert, was to develop a sustainable and cost-efficient crate that delivers high performance. The results look very promising for our daily operations, using polyAl crates made from approximately 200 recycled beverage cartons each.”
Aseptic beverage cartons are made up of, on average, 70% paperboard made from wood sourced from FSC™ certified forests and other controlled resources. The remainder is made up of an ultra-thin aluminium layer that shields food from light and oxygen and thin layers of polymers that block moisture and hold the layers together. Such multi-layered structures enable the package to protect the food inside and allow for distribution and storage at room temperature.
In recycling, the fibres in the cartons are extracted at paper mills. The remaining mixture of polymers and aluminium can be turned into polyAl pellets for products such as pallets, crates, logistics packaging and outdoor furniture.
Visit the Food & Beverage Carton Alliance booth at the Plastics Recycling Show in Amsterdam on 1 and 2 April 2025 to find out more.