How Fiat, Tetra Pak & Lapo Turn Cartons into Car Interiors
Fiat has broken new ground in automotive sustainability by incorporating recycled materials from used beverage cartons into its latest vehicle.
The new Fiat Grande Panda is the first car to use a compound made from polyethylene and aluminium (polyAl), by-products of the beverage carton recycling process, in key interior components.
This collaboration between Fiat, Lapo Compound and Tetra Pak showcases the power of circular innovation and sets a new benchmark for recycled materials in car manufacturing.
Circular beverage cartons
Beverage cartons are typically made from 70% paperboard, 25% polymers and 5% aluminium.
These materials ensure products remain shelf-stable without refrigeration, thanks to ultra-thin layers of polyethene and aluminium.
While the paperboard is widely recycled into products like napkins and toilet paper, the remaining polyAl fraction has often been more challenging to reuse – until now.
Tetra Pak has been exploring commercial uses for polyAl in collaboration with recyclers and compound producers.
“The use of recycled materials from beverage cartons in the Fiat Grande Panda is a fantastic demonstration of their vast potential across multiple industries,” explains Kinga Sieradzon, Vice President Sustainability Operations at Tetra Pak.
“It's a powerful example of how sustainable solutions can drive innovation and reshape traditional manufacturing. This is a great result of collaboration.”
The efforts have led to innovative applications beyond packaging, opening the door for use in sectors such as automotive and construction.
Fiat’s recycled interiors
Fiat’s Grande Panda uses recycled polyAl in several interior parts, including the central console, dashboard and front and rear door panels.
In total, each car contains material from approximately 140 beverage cartons.
The recycled compound, Lapolen Ecotek, is produced by Lapo Compound and was developed specifically to meet Fiat’s standards for performance, durability and aesthetics.
Notably, Fiat chose to place the material in visible parts of the car interior, showcasing the bold finish created by the aluminium content.
“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.” comments Kinga.
“This collective effort is crucial for building a more circular economy and ensuring a sustainable future for our planet."
Lapo Compound also ensured the recycled material could match Fiat’s required shade of blue, proving both its technical and visual appeal.
Supporting circularity and regulatory targets
Fiat’s decision aligns with its “less is more” approach, focused on removing redundant components and reducing reliance on chrome and leather.
It also places the brand ahead of forthcoming regulations, including the EU Commission’s End-of-Life Vehicles Proposal, which calls for 25% of vehicle plastics to come from recycled materials.
The partnership with Lapo Compound demonstrates how automotive manufacturers can meet these targets without compromising on quality.
“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,” says Giuseppe Crisci, General Manager at Lapo Compound.
“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.”
The Grande Panda is already available across most of Europe, with plans to launch in other markets by the end of the year.
Lapo Compound is now exploring additional applications for Lapolen Ecotek, with trials under way in areas such as outdoor furniture and factory flooring.
This points to even greater potential for polyAl to support circular economy goals across multiple industries.
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