Coated paper cartons, typically 70–90% paperboard with thin plastic or aluminium layers, offer strength and moisture resistance but complicate recycling. Recycling begins with collection, sorting, and hydrapulping, which separates fibres from the coatings in about 20 minutes. The recovered pulp forms new paper, while plastic–aluminium residues may be reused or energy-recovered. Modern processes recover up to 90% usable fibre and save around 75% energy compared with virgin pulp production. Choosing water-based coatings and collaborating with specialised recyclers increases fibre recovery and ensures compliance with sustainability goals.