Beverage Packaging - PET vs Aluminum vs Carton: The Environmental Truth

The Packaging Dilemma: There Is No Perfect Solution

Scroll through social media and you'll see passionate debates: "Aluminum is better!" "No, carton is!" "Glass is the only sustainable option!" But here's the uncomfortable truth: there is no perfect beverage packaging material. Each has environmental trade-offs.

Let's examine the science, recycling data, and lifecycle analyses to understand what you're really choosing when you buy a beverage.

The Three Main Contenders

PET PLASTIC (Polyethylene Terephthalate)

Found in: Most bottled water, soda, sports drinks (including Akvile bottles)

Environmental Profile:

✅ PROS:

• Lightweight: Reduces transportation emissions (up to 40% less fuel than glass)
• Widely recyclable: Accepted in virtually all recycling programs
• Lower production energy: Requires less energy to manufacture than aluminum or glass
• Durable: Doesn't break, reducing waste from damaged products
• Actual recycling rate in EU: 60-70% collected and recycled

✅ When recycled: Can be turned into new bottles (bottle-to-bottle), clothing fibers, carpeting, industrial materials

❌ CONS:

• Made from petroleum: Non-renewable fossil fuel resource
• Ocean pollution: When not properly disposed, contributes to marine plastic
• Degradation time: Takes 450+ years to decompose in landfills
• Microplastic concern: Can shed microplastics over time
• Downcycling: Often recycled into lower-quality products, not infinitely recyclable

CRITICAL FACTS:

• According to PETCORE Europe, PET bottle collection rate in EU reached 64.4% in 2021
• When properly recycled, PET bottles can be recycled multiple times (but quality degrades)
• rPET (recycled PET) requires 79% less energy than virgin PET production

ALUMINUM CANS

Found in: Sodas, energy drinks, some sparkling waters (including Voss Flavoured, Josephine)

Environmental Profile:

✅ PROS:

• Infinitely recyclable: Can be recycled endlessly without quality loss
• High recycling rate: 74% recycling rate in EU (2021)
• Fast recycling: Recycled aluminum can be back on shelf in 60 days
• Energy savings when recycled: Recycling aluminum saves 95% of energy needed for virgin production
• Doesn't degrade: Maintains integrity indefinitely
• Best for circular economy: True closed-loop recycling

❌ CONS:

• Mining impact: Bauxite mining (aluminum ore) causes significant environmental damage
• Energy-intensive production: Virgin aluminum requires enormous energy (primarily from coal)
• Water usage: Aluminum production uses massive amounts of water
• Rare earth resource: Bauxite is finite and geographically concentrated
• Heavy: More fuel needed for transportation than PET
• Lining required: Most cans have plastic/resin liner (BPA-free now, but still present)

CRITICAL FACTS:

• According to Metal Packaging Europe, producing 1kg of virgin aluminum requires 15-16 kWh of electricity
• Recycling 1kg of aluminum saves 14 kWh (equivalent to running laptop for 100 hours)
• However: Initial production footprint is massive compared to PET
• Aluminum production accounts for ~2% of global CO2 emissions

CARTON (Tetra Pak style)

Found in: Some juices, milk alternatives, coconut water, some functional beverages

Environmental Profile:

✅ PROS:

• Renewable materials: 70-75% paper/cardboard (from trees)
• Lightweight: Less transportation emissions than glass or aluminum
• Lower carbon footprint: Generally lower CO2 emissions in production vs aluminum
• Aseptic technology: No refrigeration needed (for some products), saving energy

❌ CONS:

• Composite material: Made of paper (75%), plastic (20%), and aluminum (5%)
• Difficult to recycle: Multi-material design requires specialized facilities
• Low actual recycling rate: Only 26% recycled in EU (much lower than claimed)
• Deforestation concerns: Paper production requires trees (though FSC certification helps)
• Not truly sustainable: Despite "plant-based" marketing, contains plastic and aluminum

CRITICAL FACTS:

• Tetra Pak claims high recyclability, but actual recycling rates are much lower
• Requires specialized recycling facilities to separate layers
• Many municipalities don't accept cartons or separate them incorrectly
• The Alliance for Beverage Cartons and the Environment (ACE) reports EU recycling rate of only 50% for beverage cartons (but independent verification shows closer to 26%)

The Recycling Reality Check

Here's what actually happens to beverage packaging in Europe:

Material	Collection Rate	Actual Recycling Rate	What Happens to Rest
Aluminum	~74%	~74%	26% to landfill/incineration
PET Plastic	~64%	~60%	40% to landfill/ocean/incineration
Glass	~76%	~74%	26% to landfill
Beverage Cartons	~50% claimed	~26% actual	74% to landfill/incineration

Sources: PETCORE Europe, Metal Packaging Europe, FEVE (European Container Glass Federation), ACE reports

The uncomfortable truth: Even with best recycling systems, 26-40% of packaging still ends up as waste.

Lifecycle Analysis: Which Is "Greenest"?

According to lifecycle assessment studies:

Best Case Scenario: Everything Gets Recycled

1. Aluminum (infinite recyclability)
2. Glass (infinite recyclability, but heavy transport emissions)
3. PET (multiple recycling cycles possible)
4. Carton (difficult to recycle, eventually degraded)

Worst Case Scenario: Nothing Gets Recycled

1. PET (lowest production emissions, but persists for centuries)
2. Carton (biodegradable paper component, but plastic/aluminum remain)
3. Glass (inert, doesn't degrade, but doesn't pollute chemically)
4. Aluminum (massive production footprint wasted)

Real World Scenario: Current Recycling Rates

It depends on:

• Local recycling infrastructure
• Transportation distances
• Energy grid carbon intensity
• Consumer disposal behavior

General consensus from environmental scientists:

• For beverages consumed locally, PET and aluminum are roughly equivalent when considering current EU recycling rates
• For long-distance shipping, PET wins due to weight
• For true circular economy, aluminum wins (if recycling rate stays high)
• Cartons underperform due to low actual recycling rates despite marketing

What About Glass?

Glass is often cited as most sustainable, but reality is complex:

✅ PROS:

• Infinitely recyclable without quality loss
• Inert (doesn't leach chemicals)
• Made from abundant materials (sand)
• Premium feel

❌ CONS:

• Extremely heavy: Massive transportation emissions (5-10x weight of PET for same volume)
• Energy-intensive: High temperatures needed for production and recycling
• Breakage: 5-10% loss during handling/transport becomes waste
• Return system needed: Requires deposit schemes to be truly sustainable

Bottom line on glass: Best when consumed very locally with strong return systems. Not ideal for international distribution.

The Hidden Factor: Fill Efficiency

Larger formats are more sustainable regardless of material:

• 1.5L PET bottle uses ~20% less plastic per liter than 600ml bottles
• Family packs reduce packaging waste by 30-50% vs individual servings
• Concentrated products (dilute at home) slash transportation emissions

This is why Akvile 1.5L format exists – same natural mineral water, 40% less packaging per liter.

What Can Brands Actually Do?

Good practices we look for:

✅ Use rPET (recycled PET) – 79% less energy than virgin plastic
✅ Offer larger formats – family sizes reduce packaging per liter
✅ Minimize packaging weight – lightweighting reduces transport emissions
✅ Clear recycling instructions – help consumers recycle correctly
✅ Support deposit return schemes – dramatically increase recycling rates
✅ Avoid over-packaging – no unnecessary secondary packaging
✅ Local production when possible – reduce transportation

❌ Greenwashing to avoid:

• "100% recyclable" (technically true but meaningless if infrastructure doesn't exist)
• "Plant-based plastic" (still plastic, still fossil fuel derived in most cases)
• "Eco-friendly" without specifics
• Carbon-neutral claims without transparent offsetting details

The Consumer Impact: What You Can Do

Your choices matter more than you think:

1. Choose Larger Formats

• 1.5L bottle > three 500ml bottles (30-40% less packaging per liter)
• Family packs > individual servings

2. Actually Recycle

• Rinse containers
• Remove caps/lids (different plastic type)
• Follow local guidelines
• Don't "wishcycle" (putting non-recyclables in recycling hoping they'll figure it out—they won't)

3. Support Brands Using rPET

• rPET (recycled PET) creates demand for recycled materials
• This makes recycling economically viable
• Closes the loop

4. Consider Total Impact

• Local product in plastic < Imported product in aluminum (when considering transport)
• Larger format in PET > Individual cans (less total packaging)

5. Reusable Options When Possible

• Refillable bottles for home
• But don't shame yourself for buying packaged beverages when needed—we're all human

The NoBullshitDrinks Position

We don't greenwash. Here's our honest assessment:

Why we stock products in PET:

• ✅ Lightweight – Lower transport emissions from Lithuania/Norway to customers
• ✅ Widely recyclable – 64% collection rate in EU, better than cartons
• ✅ Practical – Doesn't break, safe for families and outdoor use
• ✅ Lower energy – Less production energy than aluminum or glass
• ✅ Larger formats available – 1.5L family size reduces packaging per liter

Why we stock products in aluminum:

• ✅ Infinite recyclability – True circular economy potential
• ✅ High EU recycling rate – 74% actually recycled
• ✅ Premium experience – Some products (Voss, Josephine) use cans
• ✅ Portable format – 330ml cans for on-the-go

What we wish existed:

• Universal deposit return schemes (increases recycling to 90%+)
• Mandatory rPET content in all bottles
• Standardized packaging for true circular economy
• Better infrastructure for carton recycling

The Bottom Line

What science shows:

• No perfect packaging – all have environmental trade-offs
• PET and aluminum are roughly comparable at current EU recycling rates
• Larger formats are better regardless of material
• Actual recycling matters more than theoretical recyclability
• Cartons underperform despite "eco-friendly" marketing

The honest truth: The most sustainable drink is tap water in a reusable bottle. But we're realistic—people want variety, convenience, and functional benefits.

Our approach: Stock products in packaging that:

1. Can actually be recycled in existing infrastructure
2. Minimizes weight (transport emissions)
3. Offers larger formats (less packaging per liter)
4. Comes from brands investing in sustainability

And always:

• No greenwashing
• Clear recycling instructions
• Honest about trade-offs
• Supporting deposit return schemes

Want to make a sustainable choice?

• Choose larger formats (1.5L > 600ml > cans for same product)
• Buy what you'll actually consume (food waste > packaging waste)
• Recycle properly
• Don't let perfect be the enemy of good

[Shop Responsibly →]

References:

• PETCORE Europe - PET Collection & Recycling Statistics 2021
• Metal Packaging Europe - Aluminum Recycling Report 2021
• FEVE (European Container Glass Federation) - Glass Recycling Data
• Alliance for Beverage Cartons and the Environment (ACE) - Recycling Reports
• Environmental Protection Agency (EPA) - Packaging Lifecycle Analyses