Amcor has worked with French organic food producer Alter Eco to develop a reduced-weight, paper-based packaging solution for Alter Eco’s 200g chocolate bar range sold in France.
The new packaging replaces the previous format, which used a cardboard sleeve and inner aluminium foil, with a single paper-based solution. According to the companies, the redesign was aimed at reducing packaging weight while maintaining product protection and shelf presentation.
Alter Eco sources organic cocoa through cooperatives of small-scale farmers and said packaging was identified as an area for improvement within its wider sustainability strategy. The company set out to redesign packaging across three 200g chocolate bar variants available on the French market.
Amcor supported the transition using its AmFiber™ Performance Paper, a paper-based material designed to provide barrier protection for applications such as chocolate. The solution was developed in collaboration with Alter Eco and Swiss chocolate manufacturer and co-packer HALBA.
One of the redesigned products contains whole almonds, which required the packaging to maintain a smooth appearance despite the chocolate’s textured surface. Amcor said this requirement was addressed while maintaining protection against moisture and grease.
The companies said the new packaging delivers a weight reduction of up to 61% compared with the previous format. The fibre used is FSC®-certified and the packaging can be recycled in the paper stream in France, where appropriate recycling infrastructure exists. The solution also aligns with CEPI and 4evergreen guidelines.
“This project illustrates our commitment to innovation, combining reduced environmental impact with uncompromising quality. Designing a thinner packaging that still protects the chocolate and preserves its organoleptic qualities is a true technical challenge and a major step forward for Alter Eco,” said Anne Descarsin, R&D pack manager at Alter Eco.
Janice Narainsamy, senior product development engineer at Amcor, said, “Paper-based packaging combines strong shelf appeal with a well-established perception of sustainability. With the right barrier performance, it can also deliver the protection needed for demanding applications like chocolate. Alter Eco’s transition to AmFiber™ Performance Paper demonstrates this in a real market context, delivering a significant reduction in packaging weight.”
Amcor said weight reductions vary by product, with a 37% reduction for the dark dessert chocolate and 61% reductions for the dark chocolate with whole hazelnuts and whole almonds.
