Aseptic Packaging at GLS Elopak: How Engineered Precision Extends Shelf Life

Shelf life is engineered through material science, sterile processing, and rigorous quality control, ensuring reliability and consistency.

In aseptic packaging, both the product and the carton are sterilised separately and sealed in a controlled environment. This closed system allows liquid foods to remain shelf-stable for six to twelve months under ambient conditions, without preservatives or refrigeration.

This principle defines how GLS Elopak operates. A joint venture between India’s GLS Group and Norway-based Elopak, the company brings globally proven aseptic carton technology to industrial-scale manufacturing, protecting liquid foods so that taste, nutritional value, and product safety remain intact from filling to final consumption.

To support growing brands, GLS Elopak manufactures over 5 billion packs annually, with capacity scalable to 10 billion, enabling consistent, high-volume supply for dairy, juices, functional beverages, and liquid nutritional products.

GLS Elopak’s flagship Pure-Pak® and Alpak® cartons are engineered with a six-layer high-barrier structure for superior product protection.

Food-grade polyethylene layers ensure hygiene and secure sealing, an aluminium foil layer blocks oxygen and light, and a renewable paperboard core provides strength and dimensional stability.

Together, these layers create a protective internal environment that preserves product quality throughout storage, transportation, and distribution.

Backed by internationally recognised certifications including ISO 9001, ISO 22000, BRC, and ISO 14001, GLS Elopak delivers aseptic packaging aligned with global food safety, quality, and sustainability standards, reinforcing long-term brand reliability and consumer trust.

Below are eight clearly defined, technology-led aspects that support shelf stability in GLS Elopak’s aseptic packaging and outline how it differs from conventional packaging approaches.

1. Aseptic Packaging Built on a Six-Layer Protection System

Aseptic packaging from GLS Elopak is built around a six-layer carton structure designed to support the safe storage of liquid food under ambient conditions.

Each layer has a defined function, working together to help maintain product quality from filling through distribution and storage.

This multi-layer construction supports protection against external factors such as light, oxygen, and moisture, helping preserve taste, safety, and nutritional integrity throughout the intended shelf life.

The Six Layers and their Functions

1. Inner Polyethylene (PE) Layer

The innermost layer comes into direct contact with the product. It provides a secure seal and helps maintain hygiene by forming a protective barrier between the liquid and the rest of the packaging structure.

2. Polyethylene (PE) Binding Layer

This layer acts as a bonding interface, connecting the inner PE layer to the aluminium foil. It helps stabilise the carton structure and supports consistent performance across layers.

3. Aluminium Foil Layer

The aluminium foil serves as a key barrier layer, helping protect the contents from light, oxygen, and moisture, factors that can influence product quality and shelf stability over time.

4. Polyethylene (PE) Layer

Positioned between the aluminium foil and the paperboard, this layer connects the barrier layer to the structural core of the carton, contributing to overall durability.

5. Paperboard Layer

Made from wood pulp, the paperboard provides strength, rigidity, and shape to the carton. This layer supports handling, transportation, and stacking during distribution.

6. Outer Polyethylene (PE) Layer

The outermost layer offers protection against external moisture and environmental exposure, supporting surface durability throughout the supply chain.

Together, these six layers form a well-balanced packaging structure that combines protection, strength, and functionality, supporting a range of long-life liquid food and beverage applications.

2. True Sterility Across the Entire Packaging Process

Shelf life depends as much on process control as on material design. GLS Elopak operates one of the region’s earliest advanced aseptic manufacturing units, maintaining fully sterile conditions throughout production and packaging.

This controlled environment prevents microbial contamination without the need for preservatives.

The result is aseptic packaging that supports clean-label objectives while delivering extended shelf stability.

For brands seeking a packaging company that understands asepsis as a system, not a single step, we offer proven, certified reliability.

3. Industrial Scale that Preserves Quality, Not Just Volume

GLS Elopak’s manufacturing campus spans over 17 acres, with a current capacity of 5+ billion packs annually, scalable to 10 billion packs through ongoing expansion.

This scale allows

• Consistent quality across high-volume runs
• Supply reliability for national and global brands
• Faster turnaround without compromising sterility
• Long-term capacity planning for growing portfolios

Many packaging companies struggle to maintain uniform standards at scale. Our infrastructure is designed to ensure that aseptic packaging quality remains consistent, regardless of volume.

4. Packaging Formats Designed Around Product Reality

Our aseptic packaging solutions, including Pure-Pak® and Alpak®, are available in sizes ranging from 65 ml to 1000 ml, allowing brands to address different consumption occasions while working within a single packaging ecosystem.

Applications include

• Milk and flavoured dairy
• Juices and fruit-based beverages
• Functional and nutritional liquids such as fortified beverages, protein-based drinks, energy and wellness formulations, liquid supplements, and similar ambient-stable products.
• Institutional and retail liquid foods such as UHT milk, flavoured milk, creamers, liquid nutrition packs, portion-controlled servings, and related shelf-stable formats.

Each format can be paired with multiple closure options, tamper-evident systems, and environmentally friendly paper straws.

This flexibility allows brands to scale, diversify, and innovate while staying within a single, trusted packaging company ecosystem.

5. Sustainability Embedded into Aseptic Packaging Design

GLS Elopak’s approach to sustainability is structural, not cosmetic. Our aseptic packaging solutions are made to replace plastic bottles with renewable, low-carbon carton formats without sacrificing shelf life.

Key sustainability measures include

• Cartons made with up to 75% renewable pulp
• Recyclable material recovery through hydrapulping
• Captive solar power plants supporting manufacturing units
• Zero Liquid Discharge facilities with rainwater harvesting
• IGBC Platinum-rated green buildings

As a responsible packaging company, GLS Elopak ensures that extended shelf life aligns with environmental accountability.

6. Global Certifications that Safeguard Brand Trust

GLS Elopak’s aseptic packaging operations are governed by internationally recognised certifications, including

• ISO 9001:2015 – Quality Management
• ISO 22000:2018 – Food Safety Management
• BRC Global Standard for Packaging Materials
• ISO 14001 & ISO 45001
• Halal India certification

These standards ensure that every packaging solution meets global compliance expectations, making GLS Elopak one of the most trusted packaging companies for long-life liquid food products.

7. Beyond Packaging Supply: Complete Aseptic Solutions

GLS Elopak operates beyond the role of a packaging supplier. Its scope covers the complete aseptic packaging lifecycle.

Brands receive support across filling equipment alignment, closure system performance, technical servicing, spare parts availability, and collaborative research for new product development.

This integrated model simplifies operations. It limits supplier dependency and positions the organisation as a long-term packaging company partner rather than a transactional provider.

8. Shelf Life that Creates Commercial Advantage

Extended shelf life delivers a clear commercial advantage. Aseptic packaging enables

• Distribution without cold-chain dependence
• Reduced product wastage and returns
• Stable product quality across transport and storage
• Stronger consumer trust and repeat purchase behaviour

These benefits are the result of disciplined engineering, controlled production environments, and global packaging expertise, not assumptions.

Why GLS Elopak Leads in Aseptic Packaging Solutions

GLS Elopak exists to ensure that liquid food consumption remains safe, accessible, and appealing.

Our aseptic packaging solutions are built on technology, backed by certifications, and delivered through sustainable manufacturing.

As a packaging company with global lineage and advanced local capability, we support brands that value shelf life, safety, and long-term performance.

For brands seeking aseptic packaging that delivers dependable shelf life, operational confidence, and sustainability leadership, a capable partner makes the difference.

Contact GLS Elopak to discuss aseptic packaging solutions aligned with your product requirements, market needs, and long-term growth objectives.

FAQs

1. What makes aseptic packaging suitable for long unrefrigerated shelf life?

Aseptic packaging relies on sterile processing and high-barrier material structures that protect liquid food from oxygen, light, and microbial contamination. This controlled environment allows products to remain shelf-stable without the need for preservatives or cold storage.

2. Which products are best suited for aseptic carton packaging?

Aseptic cartons are ideal for liquid foods such as milk, flavoured dairy, juices, functional beverages, and other liquid nutritional products that require safety, quality retention, and extended shelf life under ambient conditions.

3. How does aseptic packaging support clean-label product requirements?

By maintaining sterility throughout filling and sealing, aseptic packaging eliminates the need for chemical preservatives. This allows brands to meet clean-label expectations while maintaining product safety and stability.

4. How does aseptic packaging contribute to sustainability goals?

Aseptic cartons are largely made from renewable materials and are designed for efficient recycling. Their ability to extend shelf life without refrigeration also reduces energy consumption across storage and distribution.

5. What should brands consider when selecting an aseptic packaging partner?

Brands should evaluate technical capability, material quality, process control, certifications, and the ability to provide end-to-end support. A partner with integrated solutions helps ensure consistent performance, regulatory compliance, and long-term scalability.