Technology & Industrial Integration

 

Aseptic-compatible functional carton platform

FusionPak is a patent-pending functional variant of the standard single-serve aseptic carton, designed to add a second consumption mode while preserving existing aseptic processing principles.

The concept enables a single package to be consumed as a beverage or, after freezing, as a push-up frozen product using an integrated controlled tear-zone.

Core design principle:
Extend packaging functionality while maintaining existing aseptic, sealing and filling performance standards.

Platform Design Approach

FusionPak is developed as a functional extension of existing aseptic carton platforms rather than a replacement packaging system.

The technology is built around three core industrial priorities:

  • Preserve aseptic integrity

  • Maintain compatibility with existing filling and sealing environments

  • Enable scalable industrial implementation as a format or laminate-level variant

Laminate-Level Functional Integration

FusionPak functionality is integrated directly into the laminate structure.

This approach enables:

  • No additional components such as sticks, tubes or sleeves

  • No additional secondary packaging elements

  • No additional handling steps during filling or sealing

  • Controlled tear activation only during consumer use, typically after freezing or post-consumption

From a production perspective, FusionPak is designed to behave as a standard aseptic carton during filling, distribution and storage.

Aseptic Integrity & Food Safety

FusionPak is designed to operate fully within established aseptic packaging principles.

Key design characteristics:

  • Primary aseptic product barrier remains unchanged

  • No additional product exposure before first opening

  • Structural performance maintained during transport, storage and shelf life

  • Functional behaviour occurs only during consumer interaction

The concept is therefore designed to remain fully aligned with existing aseptic validation frameworks.

Industrial Line Compatibility

FusionPak is designed for integration within existing brick carton production platforms.

Target integration model:

  • No additional stations required within aseptic zones

  • No changes to sterilisation or primary sealing technologies

  • No additional primary process steps required

  • Implementation possible as laminate or format variant

This allows packaging partners to introduce functional differentiation without requiring platform redesign.

Industrial Validation Pathway

FusionPak is designed for structured validation within existing industrial testing environments.

Typical validation areas include:

  • Mechanical integrity verification

  • Freeze–thaw performance validation

  • Transport and compression performance

  • Opening consistency verification

  • Aseptic integrity confirmation

The validation approach is designed to align with existing industrial qualification processes.

Application Scope

FusionPak is designed for single-serve beverage categories including:

  • Dairy and flavoured milk products

  • Children's beverages

  • Smoothies and fruit-based drinks

  • Water-based beverages

  • Functional and protein beverages

The platform enables freeze-ready positioning without requiring product reformulation or new production infrastructure.

Sustainability Context

FusionPak enables beverage brands to enter freeze-at-home frozen treat segments that are currently dominated by plastic tube packaging formats.

The carton-based structure remains compatible with existing carton recycling streams while supporting reduced plastic intensity compared to traditional freeze pop formats.

Industrial Value Proposition

FusionPak enables packaging partners and beverage brands to:

  • Extend existing product portfolios into frozen consumption occasions

  • Introduce functional packaging differentiation within existing supply chains

  • Launch seasonal or limited-edition concepts using current production infrastructure

  • Support premium positioning through dual-use consumption functionality

Development & Collaboration

FusionPak is currently positioned for technical evaluation, industrial validation and pilot collaboration with packaging and filling partners.

The platform is designed for OEM-friendly integration within existing aseptic carton ecosystems.

Technical Discussions

Technical discussions can start at a high level and remain non-confidential.
Detailed technical and patent information can be shared under NDA if there is mutual interest in further evaluation.