April 29, 2021

Opening of Palurec recycling plant – A milestone in beverage carton recycling

On 29 April, the Palurec recycling plant on the site of the Knapsack Chemical Park near Cologne was officially opened, heralding the dawn of a new era in beverage carton recycling. That’s because the commissioning of this state-of-the-art plant, which separates and recycles the foil mixture of polyethylene (PE) and aluminium (Al) as well as the plastic closures after the detaching of the paper fibres, has increased the recyclability of our packaging to well over 90 per cent!

Now we fetch the rest: PE-aluminium recycling of used beverage cartons

More than three million tons of beverage cartons have been recycled in Germany until today. The cellulose fibres recovered are longer and stronger than most other types of recycled paper and are thus particularly well suited for the manufacture of corrugated board.

Detaching the paper fibres creates residual materials in the paper mill. These predominantly consist of a foil mixture of polyethylene (PE) and aluminium (AL) as well as high density polyethylene (HDPE) originating from the caps. The producers of beverage cartons are now taking the recycling of this so-called reject into their own hands. For this purpose, Palurec GmbH was founded as a wholly owned subsidiary of Fachverband Getränkekartons für flüssige Nahrungsmittel e.V. (FKN), which has invested in the construction of a recycling plant. It took just under three years to build the plant, with the companies Elopak GmbH, SIG Combibloc GmbH and Tetra Pak GmbH & Co.KG investing around eight million euros in the project – an investment that will pay off in so many ways. As Palurec produces commercially viable secondary raw materials from the residual materials of beverage carton recycling – the aluminium-plastic compound of barriers and closures – this conserves valuable resources and closes the recycling loop.
”Thanks to its high content of renewable raw materials, the beverage carton is among the most climate-friendly packaging on the market. And through our unique Palurec plant concept, we have now succeeded in further improving this recyclability and, therefore, the overall life cycle of the beverage carton.”
Andreas Henn, Managing Director Palurec GmbH
”The circular economy is a key lever in preserving biodiversity and protecting our climate. If recycled paper, plastic and aluminum from the beverage carton can be used in new products in the future, this will be an important step in the continued protection of our environment.”
Jörg-Andreas Krüger, President of Naturschutzbund Deutschland (NABU)

Video on the Palurec recycling plant

From groundbreaking to commissioning in 1.5 years

Recycling Palurec Anlage Hallenbau Elopak
Bau der Palurec Anlage
Recycling Palurec Anlage Hallenbau Elopak
Bau der Palurec Anlage
Recycling Palurec Anlage Hausbau Elopak
Bau der Palurec Anlage
Recycling Palurec Anlage Halle
Aufbau und Gestaltung der Palurec Anlage
Recycling Palurec Anlage Herstellung
Außenbereich der Palurec Anlage
Recycling Palurec Anlage Herstellung
Außenbereich der Palurec Anlage
Recycling Palurec Anlage Herstellung
Aufbau der Palurec Anlage
Recycling Palurec Anlage Herstellung
Innenraum der Palurec Anlage

Beverage carton recycling – How it works:

Palurec – Why?

Palurec - Keyfact Overview

Establishment December 2017, Start of construction July 2018, Commissioning Spring 2020
Shareholder: Fachverband Kartonverpackungen für flüssige Nahrungsmittel e.V. (FKN)
Location: Knapsack Chemical Park near Cologne with 25 employees and a capacity of 18.000 tons (1st stage)
Investment: 8 m. €
Project development: KDVW GmbH & Co. KG Bielefeld, Implementation: WIPA WERKZEUG- UND MASCHINENBAU GMBH, Stadtlohn MH Immobilien Betriebs GmbH & Co. KG, Herschbach

Who is the FKN?

The association, founded in 1981 and based in Berlin, represents the common interest of the beverage carton producers: its members are SIG Combibloc, Tetra Pak and Elopak. They constitute about 95% of beverage cartons distributed in Germany and have been heavily involved in the construction and development of the recycling infrastructure of used beverage cartons since the launch of the Dual Systems. For this purpose, ReCarton GmbH was founded as early as 1991. It functions as a service provider for the dual system companies organising the sale and logistics of beverage cartons from household collections.

So what’s next?

Currently, both the certification of the Palurec plant and the application procedure at the Central Packaging Register (ZSVR), whose minimum standard sets the benchmark for determining recyclability, are underway.

Whether there will be further Palurec plants depends on numerous factors. For example, lessons learned from the plant, how demand develops in the market for recycled materials, and to what extent companies in the recycling industry become engaged. In any case, inquiries from paper mills throughout Europe are currently revealing a great deal of interest in recycling solutions.
There are three other comparable large-scale plants in Europe. Together with Palurec, this means that an annual capacity of around 50,000 tons is now possible. This equates to around one-third of the volume of beverage cartons currently produced.
FKN Press release
FKN Website
Palurec Website
McBride, Italy

Cleaning reimagined: Actiff refill packs in D-PAK™ cartons

McBride is launching new refill packs for its household cleaning brand Actiff in D-PAK™ cartons in Italy. By introducing carton packaging, the company underlines its commitment to sustainability and innovation while responding to evolving consumer expectations.

The Actiff range includes 1litre cartons for laundry detergent and fabric softener, as well as 500 ml cartons for dishwashing liquid. By making the switch, McBride reduces the use of plastic, supports recycling and offers consumers a practical and attractive alternative to conventional plastic packaging – while ensuring strong shelf visibility.

Polmlek Group Jibal, Morokko

New to the market: Jibal launches first kefir in PurePak® cartons in Morocco 

Jibal, the Moroccan subsidiary of the Polmlek Group, introduced its first kefir in PurePak® cartons to the Moroccan market in autumn 2025. The premium launch targets healthconscious consumers and addresses the growing functional dairy segment in North Africa. With this market entry, Jibal adopts a premium positioning and uses the PurePak® carton as a packaging solution strongly associated with freshness, naturalness, and health. The product launch marks an important milestone for the brand and supports Polmlek’s expansion in one of the region’s most dynamic growth markets. 

Ehrmann Cornish Dairy, UK

Freshness re‑packaged: Trewithen Cream in Pure‑Pak® cartons

Ehrmann Cornish Dairy, home to the Trewithen brand, is converting three of its fresh cream products from HDPE plastic bottles to Pure‑Pak® cartons from Elopak. In collaboration with Elopak, a new filling line has been installed at the company’s site in the Glynn Valley as part of a significant investment following the acquisition by the Ehrmann Group.

From this autumn, Cornish whipping cream, double cream and buttermilk will be available in 300 ml, 500 ml and 1,000 ml cartons. By making the switch, Trewithen reduces its use of plastic, simplifies logistics and offers retailers a sustainable, shelf‑ready alternative. The move marks an important milestone for the heritage brand and has already secured a nationwide Tesco listing across the UK.

H2O4U, Finnland

Pure water, newly packaged: JÄÄDE in Pure‑Pak® cartons

The Finnish company H2O4U is introducing JÄÄDE, one of the purest waters in the world, for the first time in fibre‑based cartons from Elopak. The naturally filtered mineral water is filled at the company’s production facility in Lahti, Finland, where it originates from deep glacial formations that were formed around 10,000 years ago.

The products are available in 330 ml and 500 ml Mini Pure‑Pak® cartons. By introducing carton packaging, H2O4U is choosing a sustainable alternative to conventional plastic packaging and reinforcing its commitment to providing clean and safe drinking water in a resource‑efficient way – while ensuring strong shelf visibility.