space during distribution. Consumers are increasingly aware of their environmental impact. The Tetra Classic Aseptic 65ml Cube, responding to this, is designed to enhance distribution efficiency. The dimensions of the package have been designed to allow every six packages to form a cube, hence optimising the use of space in distribution and storage, bringing significant improvement in cost efficiencies and the environmental footprint.” Mr Gierow echoes the importance of sustainability to consumers and highlights consumer mobility as an important driver. “On a global scale, with rising middle classes, people are no longer driven purely by price but by the promise of better sustainability, health, quality and experience. At the same time, the demand for nutritious and affordable food products is growing. Due to shifting demographics and rapid urbanisation, consumers are living more on-the-go lifestyles, which is impacting the way they consume products. They are seeking convenient packaging solutions that are not only easy to use but enhance their experience and reduce their impact on the environment.” But consumers want convenience as well as sustainability, and recent innovation has been directed at conveniently complementing the patterns of daily life. Tetra Pak’s DreamCap is a good example – the ‘Edge’ refers to the slanting top of the package, which is designed to improve the liquid flow and provide space for a large opening on the small, on-the-go carton formats. In addition, consumers like information to be easily accessible. In this respect, Mr Krashak believes that smart packs offer rich potential for a consumer experience. “Every pack sold can carry a unique digital identifier, creating the opportunity for direct one-to-one conversations with consumers,” he remarks. “Our research has also shown that consumers are increasingly looking for novelty and fun in their products, as they use consumption as a means of expressing themselves. The Tetra Pak Index 2018 reveals that brands are expected to appeal to consumers on an ever more personal level, with customisation of products and personalisation set to be key differentiators moving forwards.”
only be achieved by securing greater asset optimisation, configuring the optimal long-term infrastructure that can flexibly handle any operational demand. This is only possible with an optimal production setup, perfectly harmonised processes and a fully automated integration – from raw material intake to shipping finished goods. It’s crucial to get the most out of filling units, reduce the risk of downtime and to connect, automate and monitor lines, while driving down costs.”
Reducing the environmental impact All three manufacturers agree that aseptic carton packaging plays an important role in reducing food waste and minimising the carbon footprint. Ms Gasperini points out: “Aseptic packaging does not require refrigeration and thus saves energy in the storage of the product. Food waste is a primary concern and aseptic packaging helps to reduce food waste by allowing for extended shelf life, whilst keeping the product fresh and maintaining nutritional value. Beverage cartons are lightweight and easy to transport.” “Complemented by resealable closures, these packages can further help extend the life of products and reduce waste in the home,” Mr Krashak adds. Mr Gierow highlights independent life cycle assessments that he claims have shown a better environmental performance by aseptic cartons than glass, HDPE or PET bottles, pouches and cans. “Aseptic cartons are made from 70-80 per cent liquid packaging board, which comes from wood. This means the LPB in our packs has a very low carbon footprint compared with other packaging materials. Secondly, the efficient shape of aseptic cartons means that after filling they can be stacked together closely with minimal wasted space. A trailer of filled carton packs carries around 95 per cent content with just five per cent of the space taken by the packaging. This makes cartons more efficient to transport than round shapes, such as bottles, resulting in fewer trucks on the roads, less fuel used and less space needed to store the products.”
Beverage carton 4.0
Overcoming challenges with innovations
Consumers are also increasingly vociferous in their desire for assurance about product security – and the added value of traceability is hastening investment in digital manufacturing technologies with wider benefits at the bottom line. Automation is now at full swing in the industry, and Tetra Pak for one is introducing its ‘factory of the future’ human–AI collaboration vision at the Hannover Messe as we go to press. “As filling plants and factories operate on an unprecedented scale, production lines need to be more flexible, individualised and agile to handle periods of higher outputs and faster product changes,” Mr Gierow comments. “This can
With consumers increasingly conscious of the problems associated with packaging waste, circularity has emerged as a major focus for innovation. Elopak’s director of strategic marketing & product management, Paul Sweeting highlights the Pure-Pak® Aseptic system for UHT products and the EPS120A filling machine from Elopak: “In August 2017 Elopak launched PurePak® cartons with Natural Brown Board, giving a natural feel and look to the carton, whilst removing layers and improving environmental impact. Consumers instinctively choose this as a more sustainable product and some customers have converted from plastic bottles to using this package. The Pure-Pak®
| 28 | Packaging Europe