With legislative and consumer demands for more environmentally-responsible packaging, now is the time for confectionery producers to give serious consideration to their packaging material choices. Suzanne Callander reports on some of the options. 

The European Packaging and Packaging Waste Regulation (PPWR) has certainly brought the need for more sustainable packaging into sharp focus for the confectionery industry. The regulation sets clear targets to promote circularity and improve plastic recycling across Europe, requiring the design of packaging that is recyclable, and by 2030, all packaging will need to be fully recyclable or reusable.  

Offering some insights into the PPWR Regulation, Konrad Wasserbauer, Global Director Circular Economy & Sustainability at Greiner Packaging, explained that the purpose of the regulation is to reduce packaging waste, promote recycling and increase the use of recycled materials. “Many details related to its implementation are still undetermined and will be specified in the coming years through secondary legislation,” he says. “The European Commission is currently working on almost 50 such acts which detail, for example, how to calculate percentages of recycled materials or which design-for-recycling criteria must be fulfilled. Most of these secondary laws are expected to be developed between 2026 and 2028.” 

However, Konrad highlighted a key element of the new regulation – that packaging must be designed from the start to be recyclable. “Article 6 of the PPWR stipulates that packaging materials must meet certain design criteria to be considered recyclable – a concept known as ‘design for material recycling’. This means that materials and packaging designs must be chosen so that they can be integrated efficiently into existing recycling processes.”  

For confectionery producers this means that, in the future, only packaging materials that meet these requirements may be brought on to the market so it is important to ensure that the packaging materials chosen today will continue to conform to requirements in the long term. 

Standards developed by the European standardisation institute (CEN) are playing a central role in deciding which packaging materials will be considered recyclable in the future. In addition to design criteria, they include reference processes for sorting and recycling that facilitate uniform assessment. This method is based on a traffic-light system that sorts packaging materials into different categories – from easy to recycle (green) to non-recyclable (red). 

The Joint Research Centre (JRC) is supporting this process and converting the traffic-light system into a metric system in a second step. This can be used to evaluate the recyclability of the packaging, expressed in mass percent, and to assign it to one of the categories defined in the PPWR – such as A, B, or C. “This two-step process will be developed by 2028 and will form the framework for classifying packaging materials under the PPWR,” confirms Konrad. 

With PPWR looking set to have a very wide impact, its content needs to be followed and understood by everyone producing or using packaging. The regulation will embed sustainability criteria as a condition of EU market access. Crucially, it means that packaged goods that do not align with the requirements of PPWR will not be allowed on the EU market. 

Innovation is no longer optional

While currently there are still some elements of uncertainly within the PPWR regulation, which makes the choice of packaging solutions more challenging, one thing is certain – consumers are increasingly expressing a strong dislike for plastic packaging, with many now also willing to pay more for products that embrace more environmentally-friendly packaging materials. This means that, for confectionery manufacturers, packaging innovation is no longer optional – it is essential. “Brands today face a complex balancing act,” says Rasel Khan, Sales Manager for Packaging Materials at Stora Enso. “There are regulatory pressures to reduce plastic, rising sustainability expectations from consumers, and the need to preserve product quality across long supply chains. The market is looking for lightweight, strong, and visually appealing packaging solutions that lower carbon emissions.” Stora Enso believes that its Performa Nova offering delivers on all fronts, helping brands reduce CO₂ emissions, maintain structural integrity, and support traceable sustainability claims-while also enhancing shelf appeal. The lightweight fibre-based packaging board is said to offer a good print surface and natural moisture resistance which makes it well suited to use in chocolate and confectionery applications.  

Maintaining functionality 

While agreeing that sustainability is currently a key driver for packaging material innovation, Coveris argues that it is also vital that any new packaging should maintain its performance, functionality, and consumer-friendly features. “We are seeing an increasing number of brands now adopting paper or mono-material plastic packaging to simplify recycling processes,” says Melinda Bonamour, Market Development Director Paper at Coveris.  

Coveris believes that the first important step in this evolution is a move towards mono material packaging. Its argument for this is that, by simplifying material structures, confectionery manufacturers can significantly reduce packaging waste and enable easier recycling at the end of the product’s life cycle. 

Coveris can, for example, offer its MonoFlexFibre Plus solution – a fibre-based, flexible material that is said to help maintain the freshness and quality of confectionery products while also being fully recyclable within existing paper recycling streams. The material is said to offer a fibre-based structure with a natural look and feel, a range of barrier properties to suit different product needs, and sealing and printability across rotogravure, flexographic, or even digital processes. It is versatile, accommodating various sizes and weights of food contact materials (FCM), and is available for both form-fill-seal (FFS) applications and pre-made bags. 

“However, if the product application requires it, hybrid packaging – which we define as being a combination of two or more materials – can also provide a good solution,” continues Melinda. Far from being a compromise, she argued that hybrid formats can offer significant benefits, including enhanced barrier protection, extended shelf life and improved usability. “Importantly, the right hybrid packaging can also support sustainability goals. By carefully selecting compatible materials and ensuring they are easily separable, it is possible to design hybrid solutions that align with recycling systems and legislation,” argues Melinda. “This means that confectionery producers do not have to choose between performance and environmental responsibility – it is possible to have both.”  

Melinda highlighted that the move to hybrid packaging will often demand considerable technical expertise pointing out that Coveris has supported many confectionery manufacturers in making this switch smoothly and efficiently. “By taking an individual approach to each product and application, we are able to recommend the most suitable alternatives that enhance recyclability and environmental performance,” she says.  

Hybrid solutions 

Figures provided by Statista show that more than 73% of paper and cardboard packaging was recycled in 2023 in the UK, compared to around 53% for plastic-based packaging.  

These figures put up a good argument for the use of hybrid packaging materials in confectionery applications. According to Paul Wormald, Regional Sales Director for Functional Paper and Films at Mondi, hybrid packaging materials can offer a practical and forward-looking solution that aligns with market, regulatory, and operational requirements.  

“Hybrid packaging can also enhance brand positioning by offering a more natural, premium look and feel, that appeals to consumers, especially in the organic and premium confectionery segments,” says Paul. He pointed out that hybrid packaging, which combines paper with a small amount of plastic or barrier, also works well on most existing packing machines, so it doesn’t usually require big changes to production equipment, while helping brands prepare to meet new regulations. “Overall, hybrid packaging can provide a practical, good-looking, and future-proofed option for confectionery brands,” argues Paul. 

Mondi advises that the main priority when looking for more sustainable confectionery packaging should be making sure that the packaging protects the product properly.  

Different products will need different levels of barrier protection. Mondi offers a full range of paper-based hybrid solutions with different barrier levels and sealing options – heat or cold seal – designed to match specific requirements. For example, low-barrier applications, like coated products or products already in a protective wrapper, might only need a light paper-based option, while snack bars like granola or nut bars, may require high-barrier materials. Mondi works closely with its customers to understand specific product needs and also makes sure that the materials will also run well on packaging lines so there is no loss of speed or efficiency of the packaging operation. “In many instances of working with new customers, we have found that their existing packaging is more complex than necessary. Often it is discovered that a simpler, more sustainable hybrid packaging solution can offer the same shelf life, better recyclability, and strong branding potential,” says Paul. 

Getting the right blend 

Jeff Minnette, Senior Director of Technology and Strategic Development at Jabil Packaging Solutions, explained more about the use of hybrid packaging in the food industry. “To meet the need for recyclable but functional plastic packaging, scientists and designers have had to create and innovate new materials,” he says. “Let’s say a material has a very high oxygen barrier but a very low moisture barrier – materials scientists are now able to create a blend of additives that compensate for the characteristics that a substrate lacks.” 

Jeff pointed out that consumer behaviour also needs to be part of the equation – is the product easy to compost? As do economic challenges – compostables are more expensive than traditional plastic – which that can limit the applicability of compostable packaging. “For the most part, it appears that CPG brands have turned their focus to package weight reduction, the use of post-consumer recycled (PCR) materials, and creating recyclable packaging,” says Jeff. 

Hybrid packaging solutions are growing in popularity today and can offer an environmentally friendly alternative to traditional plastic packaging. By combining materials, it is possible to reduce the plastic content. 

According to Jeff, hybrid packaging allows brands to create lighter versions of heavy packages and recyclable versions of already-lightweight packages, like pouches. 

Jabil Packaging Solutions, for example can offer a hybrid package called FusePack, which combines the benefits of a lightweight flexible pouch and a rigid container. FusePack’s rigid interior frame defines the container’s shape and provides structural integrity, while the in-mould or paper panels enclose and protect the product as well as a traditional plastic container. “This combination of materials allows the package to be handled, sorted and reprocessed in a standard recycling centre or materials recovery facility (MRF). FusePack is smaller, and on average, 50-70% lighter than comparable rigid packs,” says Jeff.  

In praise of mono materials

According to Aropack, packaging pouches made from compostable films and recyclable mono-material plastics, will appeal to today’s environmentally friendly consumer. With growing consumer demand for convenience, candy pouches made from flexible packaging materials can also offer resealable closures, ensuring product freshness and reducing waste.  

The company believes that mono-material packaging offers a practical path forward to help reduce environmental impact and simplify recycling.  

Mono-material packaging refers to packaging made from a single type of material – for example polyethylene (PE) or polypropylene (PP) – instead of laminated layers of different materials. Aropack pointed out that, while traditional flexible packaging combines multiple films, each with a specific function, that mix can make it more difficult to recycle and that mono-materials can be sorted and reprocessed more easily, so less packaging waste ends up in landfill and more material is reused. 

Aropak is also seeing demand for sustainable packaging such as edible packaging, paper-based packaging and mono-material packaging, gaining traction. For confectionery manufacturers navigating modern packaging challenges, it believes that mono-material packaging offers a solution that can deliver on sustainability, supports the circular economy, and keeps organisations ahead of regulatory and consumer expectations. 

Which way to go?

With regulatory and consumer demand for more environmentally responsible products continuing to rise, sustainable packaging has become a central issue for confectionery manufacturers. Fortunately, the packaging industry can offer a wide variety of viable material solutions. 

Mono-materials, made from a single type of polymer, such as PE or PP, are gaining popularity due to their ease of recyclability and compatibility with many existing recycling infrastructures. These materials appear to be well-suited to products with simpler barrier needs – such as hard candies or certain chocolate applications – and work well with modern, high-speed form-fill-seal machines—provided they are properly calibrated. 

Hybrid-materials, by contrast, combine different materials to achieve high-performance barriers against moisture, oxygen, and light, which can offer solutions for products with complex preservation requirements. The design of hybrid materials is key as it is important that the material is designed for separation or is only used in regions with recycling systems that can cope.  

The decision between mono- and hybrid-materials is likely to revolve around two key factors – product protection and equipment compatibility. Manufacturers with the ability to upgrade machinery may find it easier to adopt mono-materials and meet recyclability targets. Others may choose hybrid solutions that extend product life while investing in offsetting programs or developing take-back schemes. 

Ultimately, the path to sustainability in confectionery packaging lies not in a one-size-fits-all solution, but in smart, product-specific choices that align performance with environmental responsibility. Early engagement with packaging suppliers and machinery experts is key to navigate this shift and to stay ahead of both regulatory and consumer expectations. 

 

Editorial contact:
Editor: Kiran Grewal kgrewal@kennedys.co.uk