Novel FusionPak carton enables dual consumption modes for aseptic beverages
A new patent-pending carton design for single-serve aseptic beverages introduces functionality that enables consumers to either drink the product fresh or freeze it at home and consume it as a push-up frozen treat. FusionPak, designed for 125 ml and 200 ml formats, incorporates a controlled tear-off zone directly into the package structure.
Laminate-level functionality maintains processing compatibility
The technology operates entirely at the laminate level, requiring no modifications to existing aseptic filling lines. When frozen, the carton opens cleanly through the engineered tear zone whilst maintaining structural integrity during standard storage and distribution. This approach allows beverage manufacturers to introduce freeze-ready stock keeping units without capital investment in new filling equipment.
The format targets multiple product categories including children’s beverages, dairy and flavoured milk, smoothies, fruit drinks, water-based beverages, and protein-based functional drinks. The design eliminates the need for wooden sticks or separate plastic tubes typically associated with frozen treat formats.
Consumer research indicates price premium acceptance
A standalone consumer survey (N = 101) assessed market reception of the dual-use concept. Results showed that most respondents immediately understood the functionality, with a strong majority perceiving it as innovative. Purchase intent data revealed that over 60% of consumers would increase purchase frequency if products were offered in this format.
Price sensitivity analysis demonstrated that over two-thirds of respondents accepted a premium above a €1 reference price. The median accepted premium measured €0.10, with a conservative average of approximately €0.13 per pack. More than a quarter of respondents indicated willingness to pay a premium of €0.25 or higher.
Material efficiency and recycling stream compatibility
From a packaging sustainability perspective, FusionPak uses significantly less plastic compared to traditional freeze pop formats, which currently rely predominantly on plastic tubes and sachets. The carton structure remains fully compatible with existing carton recycling streams, potentially offering brands a route to compete in the freeze-at-home ice pop category using fibre-based packaging.
Commercial positioning and market applications
The technology enables brands to reposition existing beverage formulations as freeze-ready products without reformulation. Potential applications include seasonal product launches, family-oriented product propositions, and premium line extensions. For packaging suppliers, the concept represents a value-added laminate innovation that introduces functionality not currently available in standard carton portfolios.
The dual-consumption platform allows single products to serve multiple usage occasions: immediate consumption, inclusion in packed lunches, or preparation as frozen treats. This multi-moment functionality may support premiumisation strategies whilst extending portfolio reach without requiring new product development.
FusionPak is currently positioned for partner validation and pilot collaboration, with OEM-friendly integration designed into the technology platform.
- For more information, visit: fusionpak.nl
