Plastic vs. Aseptic and Gable Top Cartons: Rethinking Recyclability and Sustainability

As brands navigate the evolving landscape of sustainable packaging, the debate between rigid plastic bottles and aseptic and gable top cartons is worth looking at more closely. While these types of cartons have long been marketed as the eco-friendly choice, recent data and regulatory developments suggest that plastic packaging offers a more practical and scalable path forward.

What California’s “Truth in Labeling” Law (SB 343) Actually Means

California’s SB 343 sets strict criteria for what can legally be labeled “recyclable.” In August 2025, CalRecycle updated its Material Characterization Study, confirming that aseptic and gable top cartons now meet the 60% sortation threshold, up from 47%. This means they technically qualify under California’s collection and sortation requirements.

However, CalRecycle does not determine recyclability claims—that’s a legal decision for each company and its counsel. And while How2Recycle currently lists aseptic and gable top cartons as “Widely Recyclable,” the Recycling Partnership’s 2025 data shows national acceptance at only 49%, well below the 60% threshold. If rates don’t improve by 2026, aseptic and gable top cartons will be downgraded to “Check Locally,” creating confusion and compliance risk for brands.

Consumer Preference: Bottles Win on Convenience

According to Mintel’s 2025 Global Consumer Trends, consumers increasingly prioritize convenience, clarity and authenticity in packaging. Plastic bottles are:

• Easy to recycle curbside;
• Portable and resealable; and
• Trusted by consumers for everyday use.

While aseptic and gable top cartons may appear sustainable, their limited recycling access and lack of transparency make them less practical for modern shoppers.

True Recycling at Scale

Rigid plastics like PET and HDPE are:

• Widely accepted by over 89% of U.S. recycling programs;
• Efficiently processed into new bottles and products; and
• Compatible with existing infrastructure, unlike aseptic and gable top cartons, which require specialized facilities.

This means plastic bottles offer real circularity, not just theoretical recyclability.

Environmental Impact in Practice

Plastic packaging continues to evolve.

• Lightweighting reduces material use and emissions.
• High PCR content helps brands meet circularity goals.
• Label-less and mono-material designs improve sortation and reduce contamination.

Aseptic and gable top cartons, by contrast, are often downcycled into wallboard or insulation, limiting their sustainability potential.

Performance & Versatility

Rigid plastics offer:

• Superior barrier properties for moisture, oxygen and light;
• Longer shelf life and better product protection; and
• Design flexibility for branding and consumer experience.

These advantages are especially critical in categories like nutritional beverages, where product integrity and shelf stability are non-negotiable.

Bottom Line: Aseptic and gable top cartons may now meet the minimum threshold, but plastic bottles exceed expectations—in recyclability, performance and consumer trust.