The sweet science: Industry explores recycled plastic and fiber-based alternatives in confectionery packaging

02 Feb 2022 --- Confectionery packaging is one of the most challenging areas of packaging for improving environmental sustainability. Usually composed of single-use plastic, the industry is increasingly facing challenging odds in sourcing recycled and recyclable materials to package chocolates and sweets.

PackagingInsights looks at how key industry players are tackling the issue amid ever-tightening legislative boundaries and how NGOs and charities are spotlighting new ways to improve the flow of recycled content and reduce associated carbon emissions. 

Barrier challenges 
Sam Murphy, marketing manager of Foxpak Flexibles, a UK-based confectionery packager, explains that “like many food products, the main challenge with creating [environmentally] sustainable packaging is finding an environmentally friendly alternative that will protect and preserve the product like traditional mixed plastics.” 

“In the case of confectionery, shelf life and barrier properties are a big influencer when it comes to making the right packaging choice. As a manufacturer, we are faced with the challenge of producing high-performing packaging solutions made from more [environmentally] sustainable materials.” 

Foxpak’s Generation Green fiber-based confectionery packages.Murphy says Foxpak has tried to develop an [environmentally] sustainable alternative to its commonly used laminates. The company has also created compostable packaging made with bio-based and synthetic polymers. 

“For example, we have switched from a foil-based laminate to a single polymer polyethylene structure with an EVOH (Ethylene-vinyl alcohol copolymer) barrier. This structure is considered widely recyclable across our key markets and in some cases can be recycled domestically.” 

Legislative hurdles and paper 
With the onset of the EU Single Use Packaging Directive (SUPD) and other legal breakthroughs, such as the impending UK Plastic Packaging Tax, which will impose fines on packagers failing to use a certain level of recycled plastic in each product, Murphy asserts confectionery pack design has had to make a radical shift in a relatively short period of time. 

“This [the UK Plastic Packaging Tax] has persuaded some confectionery brands to move from plastic to paper laminates. However, removing all plastic from confectionery packaging is not always feasible,” she explains.

However, the company’s Generation Green confectionery packaging line offers a range of paper-based options used for dried foods, seeds, cereals, coffee, tea, pet treats and other items. 

The paper is “ethically sourced” fluorocarbon-free white paper, resistant to water, water vapor and grease. “It is recyclable, repulpable and degradable digital, flexo and offset printed or unprinted pouch, sachet and bag format,” says the company. 

Foxpak’s compostable confectionery packs made with bio-based and synthetic polymers.Recently, packaging giant Amcor released a paper-based packaging platform for the confectionery and snack markets branded AmFiber, which is positioned as a recyclable high barrier solution against oxygen and moisture for snacks.

Clifton O’Neal, Amcor’s director for media relations, claims the first product under the AmFiber range for the confectionery and snack markets is “recyclable in most countries.” Recycling tests have shown that over 80% of the content is recovered in the recycling process. 

Indian innovations 
Meanwhile, Indian chocolate bar brand Kocoatrait announced last year it would be enabling consumers to return their fiber-based bar wrappers directly to the brand for recycling into new wrappers. 

The consumer pays for the postage to return the packaging, while Kocoatrait foots the administrative costs to store and ship the returned wrappers to its packaging suppliers.

According to Innova Market Insights, 71% of Indian consumers are willing to pay more for environmentally friendly packaging, and 78% are even willing to switch their usual brands for a brand with more environmentally sustainable packaging.

Fiber-based frenzy
Last year, Innova Market Insights labeled “Fiber-based Frenzy” a top trend for 2021, noting that innovation in plastic-replacement fiber-based solutions is proliferating as brands explore plastic waste escape routes and new connections with the enlarging eco-conscious consumer base. 

AmFiber will debut in 2022 with a high barrier package for snacks and confectionery in Europe.Full-scale paper packaging conversions occur even in technically challenging markets like confectionery, notably Nestlé’s Smarties. Recently, Mars Wrigley enlisted Metsä Board to redesign its Maltesers box in a fully recyclable format by using dispersion coating rather than polyethylene lining in the fiber box. 

According to Innova Market Insights, a majority of global consumers believe paper packaging boasts “good” (36%) or “excellent” (35%) recyclability. Meanwhile, less than half of global consumers say plastic packaging has “good” (29%) or “excellent” (17%) recyclability.

In similar innovation, Coveris revealed last year that it is converting a “potentially revolutionary” new paper into flexible packaging for dry foods. The material’s barrier properties are reportedly competitive with conventional plastic, mitigating food waste.

Boosting plastic recycling 
A central challenge for packagers where fiber-based solutions are less feasible is to ensure recyclability and recycled content within product materials. 

Murphy says Foxpak recently launched a comprehensive range of environmentally sustainable packaging solutions to the market using recycled content. 

“The most popular of our new products is our recyclable packaging. The next logical step is to develop a recyclable packaging solution made using recycled material. As we produce packaging for the food and beverage industries, the biggest challenge we face is sourcing post-consumer recyclate (PCR) materials that meet our requirements for food safety,” she explains. Flexible plastic collection is a major problem in the UK.

Recycling flexible plastics traditionally used for confectionery items is notoriously difficult. With many companies looking to boost their eco-credentials, the supply of PCR is running dry and costs are soaring. 

Recently, PackagingInsights spoke with UNESDA Soft Drinks Europe about the boom in PCR prices (which has risen over 100% for PET in the past year) and learned that many industries, like the automobile and fashion sectors, are using recycled packaging to create an illusion of circularity within their own industries. 

Boosting flexibles for confectionery
Last year, producer compliance scheme Ecosurety and environmental charity Hubbub launched The Flexible Plastic Fund, a UK industry initiative to make flexible plastic recycling economically viable for recyclers and easier for consumers. 

The Fund immediately received £1 million (approximately US$1.4 million) in backing from Mars UK, Mondelēz International, Nestlé, PepsiCo and Unilever. 

The scheme aims to set a maximum price for recycled flexible plastics and improve collection points for disused chocolate and sweets wrappers in the UK. 

At the same time, supermarkets like Sainsbury’s are aiding recycling collection efforts by setting up drop-off points at stores throughout the UK.

By Louis Gore-Langton