Fiat Teams Up with Tetra Pak to Transform Recycled Cartons into Stylish Car Interiors

Beverage cartons are getting a second life, this time, not as napkins or paper towels, but inside the latest Fiat Grande Panda. Fiat has just become the first carmaker to use recycled drink cartons as part of the actual vehicle design, and it’s not a gimmick. It’s a full-scale material innovation.

So what’s going into these cars? Recycled layers of polyethylene and aluminium, originally found in roughly 140 used beverage cartons, are being repurposed into core interior components. That includes the central console, the dashboard, and even the front and rear interior door panels.

The magic ingredient behind this transformation is a material known as polyAl. It’s what remains after the paperboard is separated from cartons during recycling, a blend of thin polymers and aluminium. To put it in context, your average beverage carton is made of about 70% paperboard, 25% polymers, and 5% aluminium. Those polymer and aluminium layers aren’t just filler; they’re the reason your juice or milk stays fresh for weeks without refrigeration.

Traditionally, the paper portion gets turned into familiar paper-based products like tissues and toilet paper. But what about the rest? That’s where Tetra Pak’s R&D efforts come in. Over the years, they’ve teamed up with recyclers and compound producers to unlock new commercial uses for polyAl, and this Fiat partnership might be the biggest breakthrough yet.

The recycled plastic used in the Grande Panda is made with a polyAl-based compound called Lapolen Ecotek, developed by Lapo Compound. And this wasn’t a case of hidden sustainability buried deep in the vehicle chassis. These materials were selected specifically for high-visibility parts of the interior. Fiat even chose the material for its distinctive shimmer, a natural result of the aluminium content, and worked with Lapo Compound to hit the exact shade of blue they had in mind.

This isn’t just about aesthetics. Fiat’s decision ties into its broader mission of building cars that are both more sustainable and more affordable. The company is taking a “less is more” approach, cutting unnecessary components and stepping away from polluting materials like chrome and leather.

The impact? Huge. Not only does this demonstrate that recycled materials like polyAl can hold their own in terms of performance and appearance, but it also shows the potential for scaling. The Grande Panda is already available across most of Europe, with international markets coming online by year’s end.

And Fiat isn’t just ticking boxes. This move puts them ahead of the curve, especially considering the European Commission’s upcoming regulations. Under the proposed End-of-Life Vehicles directive, carmakers will soon be required to ensure that at least 25% of all plastics used in vehicles come from recycled sources. Fiat and Lapo Compound are already there.

The story doesn’t stop with cars. Lapo Compound is now exploring how Lapolen Ecotek could be used in other industries too, think outdoor furniture or factory flooring. It's early days, but the material’s strength, versatility, and visual appeal are making it an attractive option well beyond the automotive sector.

In short, this is what innovation looks like when sustainability moves from the marketing slogan to the manufacturing floor.

Giuseppe Crisci, General Manager at Lapo Compound, comments: “We believe in creating products that not only meet strict quality standards but also help contribute to a circular economy by keeping valuable materials in use. Our product innovation has successfully met this technical challenge for Fiat, which is testament to our dedication to sustainable innovation that supports a journey toward a more circular, responsible future.”

Kinga Sieradzon, Vice President Sustainability Operations at Tetra Pak, comments: “The use of recycled materials from beverage cartons in the Fiat Grande Panda is a fantastic demonstration of their vast potential across multiple industries. It's a powerful example of how sustainable solutions can drive innovation and reshape traditional manufacturing.

“This is a great result of collaboration. By working together with companies like Fiat and Lapo Compound, as well as engaging with governments and consumers, we can drive the systemic change required to expand the end market for recycled materials. This collective effort is crucial for building a more circular economy and ensuring a sustainable future for our planet."