Confectionery manufacturers face a unique set of challenges when looking to implement circular economy principles. Because many confectionery products are sensitive to moisture, oxygen, aroma loss, light exposure, and fat migration, packaging has an important role to play in preserving freshness, maintaining shelf life, and protecting product quality throughout distribution and storage. “Any move towards more circular packaging solutions will need to continue to meet these functional requirements while also addressing increasing regulatory and consumer demands for sustainability,” said Melinda Bonamour, Business Development Manager Paper at Coveris.
Coveris views circular economy principles as fundamental to a holistic and strategic approach to smart packaging design. “Our priority is to eliminate unnecessary packaging, introduce lightweight structures where possible, design packaging for recyclability, incorporate post-consumer recycled (PCR) materials wherever feasible, and ensure that every material choice continues to safeguard product quality, shelf life and food safety,” continued Melinda. “At the same time, confectionery manufacturers need to prepare for evolving legislation – including the EU Packaging and Packaging Waste Regulation (PPWR).” Whilst the United Kingdom is developing its own regulatory framework, many UK packaging manufacturers are aligning with EU PPWR and food-contact requirements to maintain access to European markets.
One of the main challenges when it comes to confectionery packaging is that the high barrier performance required for product protection has traditionally been achieved through the use of laminates, metallised films, and mixed-material structures, which are often difficult to recycle. To address this, it is important to evaluate recyclable monomaterial plastics or fibre-based solutions with functional barrier coatings that have been designed and tested for compatibility with existing recycling streams.
Melinda highlighted that the use of post-consumer recycled content presents another challenge for food-contact applications. “Mechanically recycled polyethylene (PE) and polypropylene (PP) are still difficult to use safely in direct food-contact packaging. A practical approach is therefore to introduce recycled content first in applications where it is more readily achievable – such as secondary packaging, cartons, trays, display units and transport films, while continuing to work with suppliers and technology partners on compliant food-contact recycled materials for primary packaging.”
Coveris, together with its partner Nextek, recently launched the ReCover trial plant, with the aim of developing high-quality recycled material with the potential to meet the stringent requirements for food-grade packaging applications.
Fibre-based packaging also needs to be assessed carefully. “A pack should not be assumed to be circular simply because it contains a high percentage of paper,” warned Melinda. “Barrier coatings, plastic layers, metallisation, adhesives, and wet-strength chemicals can significantly influence recyclability. For this reason, it is important to validate fibre-based packaging through recognised repulpability and recyclability testing rather than relying solely on fibre content claims.
Another important consideration is PFAS compliance. From August 2026, food-contact packaging placed on the EU market will need to comply with new PFAS restrictions under Regulation (EU) 2025/40 and related implementing measures. Confectionery producers using grease-resistant papers, moulded fibre trays or coated wrappers should review their supply chains, obtain supplier declarations, and ensure appropriate testing documentation is available. Identifying compliant alternatives early can help minimise future compliance risks.
Ultimately, the greatest challenge is balancing sustainability objectives with product protection, machinability, cost efficiency, and consumer expectations. The most successful approach is to develop a structured packaging roadmap, identifying high-risk materials, testing recyclable alternatives, conducting shelf-life and line-performance trials, securing supplier documentation and implementing changes ahead of regulatory deadlines.
Circularity in confectionery packaging ultimately requires evidence-based decision making. Manufacturers should focus on packaging solutions that are demonstrably recyclable, incorporate recycled content where safe and feasible, eliminate problematic substances, and continue to protect products from factory to consumer.
Understanding your waste
Sandra Anderson, Senior Consultant at Reconomy Connect, a brand by international circular economy specialists, Reconomy, believes that implementing circular economy principles in confectionery production should start with an understanding of where waste is being generated and taking steps to prevent this waste before it occurs. “This has become increasingly important as ingredient costs remain high, putting greater pressure on manufacturers to maximise yield and extract the greatest possible value from their raw materials,” she said.
Confectionery businesses need to take a holistic view of their operations, assessing waste across the entire production process – from incoming ingredients, packaging and pallets, through to manufacturing, storage and distribution. Identifying waste hotspots, improving segregation and exploring opportunities to rework products can help reduce costs while improving resource efficiency.
The waste management landscape is changing. For example, the rollout of mandated food waste collections under Simpler Recycling – a standardised waste collection scheme in England that mandates the same core recyclable materials be collected across the country –has increased the volume of feedstock, thereby reducing demand and lowering the value of many confectionery waste streams. As a result, the strongest commercial and environmental outcomes are increasingly being achieved by preventing waste at source rather than relying on end-of-pipe solutions.
“Collaboration and training is also key when it comes to circular economy principles,” continued Sandra. “Working closely with suppliers, waste management partners and employees can help uncover opportunities to redesign processes, close knowledge gaps and drive continuous improvement. This should be underpinned by waste data tracking, helping to pinpoint inefficiencies and target reductions more effectively. Indeed, it is those manufacturers that embed circular thinking throughout their operations will be best placed to reduce costs, improve resilience and make the most of increasingly valuable resources.”
Implementation benefits
For confectionery manufacturers, the benefits of implementing circular economy principles can span the entire value chain – from procurement and production to packaging and post-consumer recovery. Circular business models can enhance resource efficiency, reduce exposure to volatile commodity prices, provide commercial advantages by minimising food waste and packaging EPR fees, and improve the sustainability of both product and packaging.
Amie Walley, a sensor Consultant at Eunomia – a global sustainability consultancy – believes that an important first step in moving from a traditional linear model, towards a more circular and sustainable business model is to gain a good understanding of how the emerging food and packaging circularity regulations align with existing operations.
“Measures such as the Packaging and Packaging Waste Regulation (PPWR) and national packaging EPR schemes are raising packaging sustainability requirements and creating risks for businesses that are not compliant,” said Amie. “Upcoming packaging regulations tend to focus on three key areas – minimising the amount of packaging used, either through redesign or reuse; increasing the quantity of recycled content in the packaging; and designing packaging for recycling. Comparing a portfolio’s existing performance against these principles can help to identify where packaging is already as sustainable as possible, and where improvements can be made.”
Ingredient sourcing and supply chains are also coming under increasing scrutiny – and pressure. Regulations such as the EU Deforestation Regulation (EUDR) and more market-based initiatives like the Taskforce for Nature Related Financial Disclosures (TNFD) require supply chain visibility and credible strategies. The focus is not just on understanding impacts on nature, but also disruption risks to supply. “These asks will increasingly be passed down the supply chain. And, despite many headlines, sustainability reporting metrics such as scope 1, scope 2, and – challenging for many food businesses – scope 3 carbon reporting remain as relevant as ever,” continued Amie. “More specific asks from national governments may impact other areas of food supply, such as expectations around reporting and minimising food waste in the supply chain.”
The challenges
Implementing circular economy principles in confectionery manufacturing can present a number of challenges. For organisations at the start of their circularity journey, understanding the growing range of regulatory requirements and translating them into practical business actions can seem overwhelming. This can be further exacerbated by differing rules across markets, as well as increasing reporting expectations, combined with the threat of enforcement.
Operationally, manufacturing lines will often already be optimised to meet production requirements, and it can be a costly exercise to change existing operations. Alongside this, established supplier relationships and procurement processes can slow the adoption of new materials, ingredients or circular approaches, particularly where changes depend on the wider supply chain that is often outside the direct control of the manufacturer.
When it comes to packaging, designing with circular economy principles can also be challenging as the confectionery industry often relies on single use materials, made from complex materials and in formats to improve shelf presence and appeal to consumers. These formats can be difficult to recycle and may hinder efforts to meet minimisation and reuse objectives. Securing suitable recycled content can also be challenging due to cost, quality, and availability constraints.
For products and their supply chains, the priority needs to be on visibility – understanding where things are sourced from, and what risks and opportunities that presents – from diversifying supply to reformulation. Investors increasingly want to know these things because wider global volatility is increasingly impacting food production and supply, so sustainability can be linked to thinking on risk and resilience to shocks.
Amie advises that taking a step back to assess current products and packaging against the key areas targeted by emerging circularity regulations is a useful practical first step towards implementing circular economy principles in confectionery manufacturing. From there, it is a good idea to focus on the quick wins that can deliver benefits with minimal cost. “For initiatives that require significant investment or changes to production lines, developing a circular economy roadmap can help to prioritise actions over time. Setting targets and monitoring performance is also important to ensure interventions are delivering the intended outcomes,” continued Amie.
She went on to highlight the importance of strengthening supplier relations, as they often control the materials, products and data needed for compliance and reporting. “Suppliers are likely to already be responding to similar circular economy requests from other customers, so collaborating with them can accelerate progress,” said Amie. In conclusion, the transition to a circular economy should be seen as a journey, rather than a one-off task. By keeping on top of regulations, learning from your peers, and seeking expert guidance where needed, it is possible for confectionery manufacturers to successfully embrace the circular economy.
