The Lab: Beverage Cartons

What is it?

Beverage cartons—like those for drinks, milk, and juice—feel like cardboard, but they are actually a "sandwich" of multiple materials. Depending on the type of manufacturer, cartons can have aluminium (e.g., Tetra Pak) or plastic linings, alongside paper. This high-tech mix is what keeps your drinks fresh, waterproof, and safe without refrigeration.

In Singapore, millions of these cartons pass through homes and cafes every week. Because they feel like paper, they are often perceived as highly eco-friendly. In reality, they are made of these different layers bonded together, meaning the vast majority end up in the bin.

What does it feel like?

In its original state, a beverage carton material is smooth, matte, and structural. It has distinct ridges from its original corner folds, possesses high tear resistance, and holds a crease permanently.

The material at the end of its lifeline possesses a unique feel: the texture of distressed leather but the lightness of paper — somewhere in between.

Why can't it just be recycled?

This is the most important thing to understand about this material: Beverage cartons can be dropped into Singapore's blue recycling bins, but they cannot actually be processed locally. While they feel like simple paper packaging, the structural reality is a massive recycling challenge.

Why they fall through the cracks:

• Material Complexity: The paper, plastic, and aluminium layers are bonded together so tightly that they cannot be easily separated by standard recycling facilities.
• Infrastructure Deficit: Cartons collected in Singapore must be bundled and shipped abroad—primarily to specialized facilities in Selangor, Malaysia—just to be processed.
• Incomplete Recovery: At overseas facilities, only paper fibers are truly recovered. The remaining plastic and aluminium layers are typically downcycled into low-grade composite materials.

What we've learned working with it

We started working with beverage cartons in 2023, sourcing them from local cafes and our own household recycling bins. Here are our core fabrication findings:

1. Preparing the Material

Cleaning

Always start with a clean carton. Rinse the carton using water and soap to get rid of any remaining beverage residue.

Flattening

Cut open the top and bottom seals, slice down the side seam, and carefully peel off any plastic caps or spouts.

Creating the Texture

Roll the flattened carton tightly like a burrito, unroll it, and roll it again from the opposite direction to create a distinct, leather-like texture.

2. Sewing and Construction

Technical Framework

The Right Needle

Employ a sharp, heavy-duty needle.

Longer Stitches

Use longer stitch lengths. If your stitches are oo close together, they form a perforated line that causes the material to sheer and rip under tension.

No Pins

Punctures in this material are permanent. Utilize standard sewing clips or double-sided tape to hold your patterns together instead.

Finishing Edges

The inner paperboard core will degrade over time if exposed. We recommend finishing edges with a localized zig-zag stitch or protective binding/bias tape.

Adhesives

Heavy-duty adhesives (e.g., shoe glues) can be used to attach pieces together as an alternative to sewing.

What we've made from it

Our baseline application from this waste stream focuses on everyday utility. Here is what we have prototyped and constructed so far:

What's still being figured out

• Moisture Vulnerability: Finding a scalable, elegant way to completely waterproof the exposed cut edges remains our biggest hurdle to ensuring long-term product durability.
• Hardware Wear: High-tension closures (like plastic snaps) can pull out over time; testing is underway for specific utility optimizations.