Tetra Pak and Jealsa Launch First Carton for Shelf-Stable Tuna

Tetra Pak, in collaboration with Spanish seafood producer Jealsa, has launched the industry's first paper-based carton packaging for shelf-stable tuna. Utilizing the Tetra Recart 200 ml format, this sustainable alternative to traditional metal cans drastically reduces carbon emissions by 85% and optimizes logistics for global markets.

A Revolution in Seafood Packaging: Tetra Pak and Jealsa Launch First Carton for Shelf-Stable Tuna

In a historic move for the seafood and packaging industries, Tetra Pak has partnered with the Spanish seafood powerhouse Jealsa to introduce the world's first carton packaging for shelf-stable tuna. Utilizing the innovative Tetra Recart platform, this transition marks a definitive shift away from traditional metal cans—a format that has dominated the canned fish aisle for over a century.

The new packaging, initially rolled out in a 200 ml Mini format with the Swedish supermarket chain Axfood last month, is now poised for global expansion. This strategic launch not only modernizes the aesthetic of canned tuna but also addresses significant environmental and logistical challenges faced by food producers globally.

Market Trends and Shifting Consumer Demands (2024-2025)

Over the course of 2024 and 2025, the packaging industry has witnessed an accelerated push towards sustainable, paper-based alternatives, heavily influenced by stricter global packaging regulations and changing consumer behaviors. According to a 2025 market assessment commissioned by Tetra Pak through Meticulous Research, the global shelf-stable tuna market is projected to grow by 12%, reaching an estimated 12.4 billion units by 2030.

This growth reflects a rising demand for affordable, versatile, and long-lasting protein options. Consumers are increasingly favoring brands that align with their environmental values. Recent data indicates that over 80% of consumers would purchase tuna packaged in a Tetra Recart carton, while 58% explicitly prefer it over existing metal or glass alternatives.

Technical and Environmental Breakthroughs

Replacing metal cans with paper-based cartons for shelf-stable seafood requires overcoming severe thermal and barrier challenges. The packaging must withstand the retorting sterilization process while maintaining an absolute barrier against oxygen and moisture. The Tetra Recart solution achieves this while delivering unprecedented environmental benefits:

Carbon Footprint Reduction: The carton format boasts an 85% lower carbon footprint than steel cans and an 83% reduction compared to glass jars.
Emissions Savings: At an industrial scale, replacing traditional cans with Tetra Recart equates to a reduction of 21,000 tonnes of CO2 emissions per one million units produced.
Sustainable Sourcing: The packaging is constructed using up to 71% Forest Stewardship Council (FSC) certified paper, ensuring materials are sourced from responsibly managed forests.

Optimizing Logistics and E-Commerce

Beyond sustainability, the rectangular, flat-packed design of the Tetra Recart fundamentally transforms supply chain logistics. Empty cartons are fed directly into filling lines, drastically reducing inbound storage space. Once filled, the rectangular shape allows for high-density stacking.

This space optimization improves retail shelf efficiency, allowing for more product volume per cubic meter compared to cylindrical cans. Furthermore, the robust, stackable nature of the carton makes it exceptionally well-suited for the rigorous demands of e-commerce, automated warehouse handling, and direct-to-consumer meal-kit distribution.

Executive Perspectives

“This is true packaging innovation in a category that has looked the same for generations,” states Tatiana Liceti, Executive Vice President of Packaging Solutions at Tetra Pak. “With the industry's first carton for shelf-stable tuna in Tetra Recart, we are giving producers and brands a new way to stand out on shelf to protect and grow market share, support cost-competitive, scalable production, and modernize with a paper-based alternative to cans.”

Echoing this sentiment, Jesús M. Alonso Escurís, President of Jealsa, emphasized the alignment with their heritage: “In Jealsa's 68-year history in shelf-stable seafood, we have always been committed to innovation. This collaboration results in a market-leading packaging solution that aligns with evolving consumer expectations.”

Impact on the Paper, Corrugated, and Packaging Industry

The introduction of the Tetra Recart for tuna sends a powerful signal to the broader paper and corrugated packaging sectors. As major food producers pivot to high-barrier paperboard, paper mills and converters will see increased demand for specialized, retortable paper grades.

Additionally, the shift from cylindrical cans to rectangular cartons alters secondary packaging requirements. Corrugated board manufacturers will need to adapt their wrap-around case designs to accommodate the tight stacking of carton packs, optimizing pallet loads and further reducing secondary material usage. This innovation cements paper-based solutions as a viable, scalable, and superior alternative in one of the most resilient food categories globally.