Tetra Pak, a leading supplier of food and beverage processing and packaging systems, has announced the introduction of Tetra Aptiva Aseptic, the world’s first aseptic carton bottle. Tetra Aptiva Aseptic combines a carton-based sleeve with a plastic top and screw cap to offer a distinctive, innovative ambient storage package.

Designed as an alternative to plastic bottles, the Tetra Aptiva Aseptic system requires less than half the capital investment compared with a plastic filling line at a comparable capacity, while offering beverage producers operating economies ranging from 20-50 per cent lower, compared with Aseptic Polyethylene Terephthalate (APET) and aseptic High Density Polyethylene (HDPE) plastic bottles.

Tetra Aptiva Aseptic is especially well suited for the fast-growing market of on-the-go beverages distributed through vending machines, convenience stores, supermarkets and other retail channels.

Offering a distinctive, semi-cylindrical shape, the package has a wide, easy-to-drink-from opening with a re-sealable screw cap applied onto a plastic top.

Pascual, leading milk, beverages and food producer in Spain, selected Tetra Aptiva Aseptic to introduce Scapy, a new brand to enter the youth market for beverages. Launched in November 2005, Scapy is a blend of fruit juice and milk enriched with vitamins and targeted at eight-14 year olds.

“The carton bottle provides all the basic value represented by Tetra Brik Aseptic packaging and also creates visual impact with the consumer – one of the main trends for years to come,” says Cesar Diaz, marketing and business development director, Grupo Leche Pascual.

Market tested in Europe and Asia, consumers have reacted positively to the Tetra Aptiva Aseptic package, underlining its “high value image” and such functional benefits as the re-sealable cap and ergonomic grip.

During tests, consumers described Tetra Aptiva Aseptic as “appealing,” “new,” and “different” while praising the “transparency” of the plastic top portion.

“Tetra Aptiva Aseptic provides a low investment solution for both existing and new customers,” says Jerry Bengston, vice president, Premium Segment, Tetra Pak Carton Ambient.

“Customers currently using ambient carton packaging will find a natural evolution with Tetra Aptiva Aseptic carton bottles and will enjoy many Tetra Pak system benefits. For new customers, the carton bottle offers an attractive, distinctive vehicle to launch a new brand or product extension.”

The Tetra Aptiva Aseptic is manufactured on the Tetra Pak A5, a newly designed filling machine, which will be available in two versions, one for portion packs and the other for family packs.

Both versions will be able to handle juice, nectars and still drinks (JNSD), as well as liquid dairy products (LDP).

The portion pack version can produce up to 12,000 packages/an hour, while the capacity of the family pack version will be 10,000 packages/hour.
The innovative filling and forming process developed for the Tetra Pak® A5 uses rolls of familiar, carton-based packaging material as well as pre-made plastic top-and-cap assemblies.

The forming and filling process begins when the sheet of packaging material is formed around the mandrel and then induction sealed to produce a highly accurate carton sleeve ready to fuse with the pre-made top.

Within the same unit, the plastic double top is cut in half and placed on the mandrel wheel where the carton sleeve is placed over the top and mandrel. Induction sealing fuses the two parts perfectly together.

Sterilisation is carried out through a unique Tetra Pak process based on hydrogen peroxide gas. After filling, a burst of nitrogen gas is puffed into the package to minimise the oxygen content before final sealing.

The final fold, to create the distinctive Tetra Aptiva Aseptic shape and base, takes place just as the package is sealed.