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Packaging specialist SIG has introduced what it claims is the world’s first aluminium layer-free full barrier solution for multi-serve aseptic beverage cartons.

The solution builds on the success of SIG’s previously launched innovation for single-serve cartons, with over 300 million packs sold in China since 2023.

In aseptic cartons, an aluminium layer is traditionally used to protect food and beverage products from oxygen and light. While aluminium accounts for only around 5% of a standard aseptic carton, it accounts for up to 25% of its carbon footprint in a full-barrier package.

According to SIG, the structure for multi-serve cartons with no aluminium layer cuts the carbon footprint of its standard aseptic cartons by 61% when combined with forest-based polymers. The material is made of more than 80% paper, simplifying the packaging structure to only two main raw materials that can be linked to renewable sources.

The packaging material promises the same full barrier protection as standard aseptic cartons, and the same shelf life of up to 12 months. It can seamlessly run on existing SIG carton filling lines with full performance, including high speeds of up to 24,000 packs per hour on SIG filling lines for small-size cartons and up to 15,000 packs per hour on filling lines for multi-serve cartons with only minor, low-cost adaptations.

Christoph Wegener, chief markets officer at SIG, said: “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”.