SIG, a global leader in sustainable aseptic packaging solutions, has once again redefined industry standards with the commercial launch of SIG Terra Alu-free + Full Barrier, the world’s first aluminum-layer-free, full-barrier solution for multi-serve aseptic cartons. This pioneering development marks a major step in SIG’s mission to decarbonize the food and beverage packaging industry.
Following the remarkable success of SIG Terra Alu-free + Full Barrier for single-serve cartons already surpassing 300 million units sold in China SIG is now scaling this innovation to multi-serve packaging. The new solution is set to be made available to customers globally and is fully compatible with existing SIG filling lines.
A Giant Leap for Sustainable Packaging
Traditionally, an ultra-thin aluminum layer is included in aseptic cartons to shield sensitive contents from oxygen and light. While it represents only about 5% of the material composition, this layer accounts for up to 25% of the total carbon footprint. SIG’s new material removes the aluminum layer altogether while preserving full product protection and a shelf life of up to 12 months, even for oxygen-sensitive beverages such as juices, flavored milk, and plant-based drinks.
When paired with forest-based polymers, the new packaging achieves a carbon footprint reduction of up to 61%, compared to standard SIG aseptic cartons. With over 80% paper content, the packaging structure is streamlined from three to two main raw materials, both linked to renewable sources making it not only more sustainable but also easier to recycle.
Plug-and-Play on Existing Equipment
A major advantage of SIG Terra Alu-free + Full Barrier is its seamless compatibility with SIG’s existing filling equipment. The solution offers plug-and-play functionality, requiring only minor, low-cost modifications. It performs at full industrial speed, delivering up to 15,000 packs per hour for multi-serve cartons and up to 24,000 packs per hour for small-size formats—eliminating trade-offs between sustainability and operational efficiency.
“With our full-barrier material containing no aluminum, we offer a powerful differentiator for brands,” said Christoph Wegener, Chief Markets Officer at SIG. “It’s the embodiment of sustainability in aseptic carton packaging and unlocks new possibilities across a wide range of beverage categories.”
A Legacy of Firsts in Aseptic Packaging
SIG has been a pioneer in aluminum-free aseptic carton solutions since 2010, beginning with SIG Terra Alu-free for plain dairy products. The company has continually advanced the concept, expanding its portfolio to meet evolving demands for more sustainable and high-performance packaging.
To date, SIG has sold over 4 billion aseptic cartons without aluminum, including 300 million using the latest full-barrier solution. These milestones underscore the company’s industry leadership and its deep commitment to innovation-driven sustainability.
“We’re striving to create a regenerative food packaging system,” said Gavin Steiner, Chief Technology Officer at SIG. “Our roadmap includes increasing the paper content in our aseptic cartons to at least 90% by 2030, including closures, with an interim goal of 85% without closure by the end of this year.”
Leading the Path Forward
By offering a scalable, high-performance, and environmentally advanced packaging option for both small and large carton formats, SIG is not only responding to market demand but also driving the transition toward a low-carbon, circular economy in food and beverage packaging.
This bold innovation places SIG at the forefront of a global shift—where performance meets sustainability, and packaging is no longer just a container, but a critical part of climate action.