What’s not to love about a chocolate bar? Probably the only thing that today’s consumer might take a dislike to is the use of conventional plastic packaging, which cannot be recycled so is not good for the environment.
While many manufacturers have already switched to more sustainable packaging materials, the European Union’s Packaging & Packaging Waste Regulation (PPWR) legislation looks set to change the landscape of packaging for good, stipulating that as of 2030 – among other requirements – all packaging in the EU must be recyclable, ruling out multi-layer plastic as a suitable material for future chocolate packaging. So, any chocolate producers that have not already made a switch to recyclable packaging, need to consider how they can deliver on packaging that ensures optimal protection and meets consumers’ sustainability expectations.
PPWR’s goal is, ultimately, to solve the packaging waste problem in Europe and it hopes to achieve this by setting phased waste reduction targets that increase every five years, while also harmonising packaging and recycling standards across member states to make these targets feasible.
In order to hit PPWR targets, a raft of new restrictions and bans are being put in place, on plastic packaging in particular. Any packaging containing polyfluoroalkyl substances (PFAS) – ‘forever chemicals’ that are also subject to scrutiny from the European Chemicals Agency will be banned entirely. In addition, single use plastic packaging for certain fresh produce applications will also be banned.
These bans will be complemented by measures aimed at incentivising high quality recycling. While the exact legal definition of what constitutes high quality recycling is yet to be decided – a date of 1st January 2028 has been set to enact new definitions around quality grades, design for recycling guidelines, and other details – the text of the preliminary agreement indicates that packaging materials must be able to be recycled into materials of at least equivalent value.
So, what do all these measures, aimed at plastic packaging, have to do with paperisation? The answer according to packaging provider, Parkside, is nothing! And this is an important point. Paper packaging has been exempted from all PPWR measures, meaning that companies are starting to switch to paper-based solutions to sidestep all of this legislation entirely.
Parkside argued that paper does have many benefits as a packaging material – It is easy to recycle, and as such has much higher recovery rates than plastic. And, provided it is made with fibres from a sustainably managed forest, it is a renewable resource. Perhaps most importantly for chocolatiers, consumers know this, and increasingly prefer it to other materials as a result.
The paper race
This places paper as the front runner in the race to be the packaging material of the future – at least, in the European market – and this has resulted in a flurry of innovation from packaging material providers. Parkside, for example, has invested heavily in sourcing and developing new barrier coatings that improve the functional qualities of paper packaging without affecting its recyclability.
It put its paperisation knowledge into practice when working on a recyclable paper-based flow wrap solution for ethical chocolate brand, Cox & Co. The company wanted to switch away from its previous compostable bioplastic solution and into a recyclable paper-based option, without compromising on the heat seal performance, moisture, and aroma barrier properties of the packaging.
Parkside developed a solution that used thin layers of water-based coatings to create a flexible paper laminate that was tested and approved by the paper recyclability testing regime of the Confederation of European Paper Industries (CEPI).
Paperisation of chocolate packaging does not have to mean downgrading the look of packaging. Advanced techniques like using vapour deposition of aluminium or metallic pigments in ink to create recyclable metallic effects are becoming increasingly common, while new water-based varnishes that add interesting finishes and tactile effects to labels and packaging continue to emerge.
Big brands like Mars Wrigley and Mondelez have led the way in showing that paper-based packaging can deliver on the protection required by delicate chocolate bars. A very thin barrier layer is able to withstand grease stains as well as moisture penetration and ensures adequate shelf life for chocolate.
Equipment issues?
“Using new packaging materials on existing packaging equipment need not be problematic either as packaging equipment providers are working hard to find solutions,” says Torsten Sauer, Director of Sustainability at Syntegon. “Syntegon, for example, now offers the paper-ON-form retrofit kit – a paper flow-wrap forming shoulder – for its new and existing horizontal flow wrapping machines. This is able to process barrier papers from a variety of material providers without causing wrinkles, tears or cracks, thus helping ensure high-quality packaging without having to sacrifice speed and efficiency when switching from plastic to paper.”
Although the advantages of paper packaging for chocolate are obvious, the switch from plastic to sustainable alternatives can be easier said than done. Many products will require adaptations in packaging material, formats, and production processes – a transition that requires time and adjustments along the way.
The expertise of packaging and process equipment manufacturers can offer tangible advantages here. They combine industry knowledge with technological know-how and can help ensure that the transition to more eco-friendly packaging is as seamless and efficient as possible. “To this end, Syntegon has put a focus on efficient material testing to help determine the optimal design for each product. Our sustainability experts perform comprehensive analyses and material tests to define the optimal packaging material and sealing parameters before production starts. Once production is up and running, our monitoring solution, Synexio supports chocolate manufacturers to keep their processes as sustainable as possible. The Uptime and Empower packages of the digital solution come with a sustainability monitoring feature that provides data on energy consumption and waste production, supporting customers to reduce their carbon footprint – with the goal to futureproof the whole packaging process,” concludes Torsten.
Supporting change
With the Packaging and Packaging Waste Regulation (PPRW) legislation requiring all packaging in the European market to be reusable or recyclable by 2030, chocolate manufactures are having to rapidly switch to either recyclable plastic or paper packaging solutions.
Packaging providers are supporting this transition with innovative materials. Coveris, for example, can offer the MonoFlex Fibre paper-based range of flexible packaging that delivers recyclability within existing paper streams.
“As part of the Coveris No Waste strategy, our focus is on selecting the most eco-efficient and high-performing packaging for each product, rather than simply deciding between paper or plastic. By expanding our portfolio to include paper-based options and reducing plastic usage in packaging for items needing external protection, we aim to offer customers the best solution aligned with their brand vision and product requirements,” says Melinda Bonamour, Market Development Director Paper Flexibles at Coveris.
The new packaging range is divided into two categories, a single layer of functional paper, and a multilayer structure with maximised paper share. There are also several subcategories within each, both for primary and secondary packaging, all said to offer good sealing and barrier properties. “Transitioning to the paper-based structure will not require major changes in the existing machine park of our customers and has proved to be efficient and fast on common packing lines,” says Melinda. Available as pre-made bags and form, fill and seal (FFS) solutions, the MonoFlex Fibre product range offers barrier properties against grease, moisture, oxygen, light or mineral oils.
Goal achieved
A pioneer for vegan and sustainable chocolate products, The Nu Company was keen to ensure the sustainability credentials of its nucao chocolate brand and so it set out to switch all its packaging to paper, a goal that, according to Mathias Schwarz, Sustainable Packaging Engineer at nucao, it has achieved this year. “All our nucao fruits and nucao nuts chocolate products have been packaged in paper since 2022. Our five chocolate bars now also come in paper packaging, and most recently our new chocolate bars also have 100% paper packaging. We are continuing to look for ways to make our packaging even more sustainable, for example by reducing the amount of material used.
For its nucao fruits and nucao nuts packaging, The Nu Company is using Koehler NexPlus Advanced which is said to have good oxygen, mineral oil, and grease barrier, which is important when in direct contact with chocolate and nuts. The paper packaging can be placed in the paper recycling after use.
“We opted for Koehler NexPlus Advanced 75 gsm after extensive tests,” says Mathias. “In addition to product protection – which was assessed using storage tests with a subsequent sensory analysis, the fact that the paper could be recycled in the paper recycling was an important factor. Another important point for us was its rating of 19 out of a possible 20 points from environment service provider, Interzero.”
Sustainable choices
“One of the most important trends in confectionery packaging is the prominent role played by perceptions around sustainability in shaping brand reputation and consumer loyalty,” said Tomas Larsson, Head of Product Line FBB and SBS at Stora Enso. He cited a recent survey that showed 73% of consumers see sustainability as essential. “Of course, consumers need to be presented with sustainable choices for their chocolate products to be able to select the most environmentally friendly options. On top of this, consumers also expect packaging that looks appealing and preserves the chocolate’s flavour,” he continues. “We have found that it is possible to cut down raw material usage and carbon emissions without compromising the product’s technical properties.”
One example of this is Performa Light board where the reduction in carbon emissions comes from the use of Stora Enso’s FiberLight Tec technology and microfibrillated cellulose. This means that less energy and materials are needed to produce Performa Light, while its lighter weight means a lower environmental impact from transportation. “When it comes to customer experience, this material is well-suited to printing premium designs,” says Tomas. “And it can offer robust protection of the product from its taste and odour neutral nature, making it well suited to chocolate.”
A printing dilemma
The packaging strategy for a new product from The Good Chocolate Company’s had two key goals. Firstly, it wanted to create a small-sized piece of chocolate that would cost less than $2.50 and secondly it needed a package that looked beautiful and would catch consumer attention.
Glassine paper was chosen as the packaging material thanks to it being an economical choice that also provided the high impact packaging solution that was such an important element of the project.
However, initially The Good Chocolate Company had problems printing onto the glassine paper, and so was only able to print onto labels. At the time, laser printing did not allow for a lot of ink and colouring on the glassine and The Good Chocolate really wanted a glassine package that would take an imprint of the image of the goddess Victory, in six different colours for its six different chocolate flavours.
The company approached JBM for a solution. “We had yet to print such detailed, gradient artwork on glassine, but we ran tests of the required artwork with success. We were then able to move forward with this project. After experimenting with different Pantone colours, different thicknesses of glassine paper, and different image resolutions, we were able to achieve the desired result,” says Ashley Finkes, Director of Marketing at JBM Packaging.
Glassine is a pulp-based material that is often mistaken for other substrates, such as wax paper, parchment, or even plastic. When you think of paper, transparency may not immediately come to mind. But glassine is a smooth, glossy paper that is transparent, allowing the packaging contents to show through.
As a result of the manufacturing process, glassine is pH neutral and acid free. And it’s resistant to moisture, air, and grease. Because it is made from wood pulp, glassine is also fully recyclable and biodegradable – making it a sustainable material choice for packaging chocolate products.
Making cost savings
With the price of cocoa continuing to rise, chocolatiers are also looking for ways to save money without compromising product quality. Lareka highlighted that the choice of material for chocolate packaging is a cost item that is often overlooked.
There are several ways to reduce costs in and around packaging, according to Lareka. For example, designing packaging that requires less material can reduce production, storage and transport costs per packaged unit.
Cost savings can also be made in the production process of the packaging itself. Many smaller chocolatiers still pack their bars by hand. Due to the limited speed achievable, this can be a costly process per bar. In order to increase the speed of packaging, some chocolatiers choose to have the packaging arrive in the factory prefabricated – already folded and glued. This can help increase packaging speed, when compared to folding manual packaging. The trade-off here, however, is that the wage costs that are saved are often spent on the pre-made packaging instead.
Purchasing a packaging machine will overcome this dilemma. It is possible to significantly increase the speed of packaging with a machine that is also able to fold the packaging itself from an inner and outer layer, eliminating the need for pre-made packaging.
One Lareka customer indicated that it would pay €0.40 per pre-made sachet. Together with the customer, Lareka was able to design new packaging that better matched the folding principles of its machine. The customer agreed to this, with the proviso that the brand identity of the product was central and had to be preserved. The new packaging consisted of two-layer packaging with the inner layer made of aluminium foil and the outer layer of printed paper. The foil could be purchased on a roll from a supplier and the outer layer could be printed and shipped without having to perform other costly actions. The result? Material costs decreased from €0.40 per packaged product to €0.10 per packaged product. A saving of 75%. Translating this into chocolate – with an annual production of 100,000 bars – resulted in a saving of €30,000 just on the material costs of the packaging.
Editorial contact:
Editor: Kiran Grewal kgrewal@kennedys.co.uk
