Amcor, Alter Eco Develop Lighter Paper-Based Chocolate Packaging

In the food and confectionery sector, packaging plays a critical role in protecting sensitive products such as chocolate while also responding to growing sustainability and recyclability requirements. Amcor has worked with Alter Eco to redesign the packaging for Alter Eco’s 200-gram chocolate bars sold in France, focusing on material reduction, recyclability, and product protection.

Reducing packaging weight without compromising protection
Alter Eco sources organic cacao from small-scale farming cooperatives and identified packaging as a priority area within its broader sustainability strategy. The objective was to replace the existing combination of a cardboard sleeve and an aluminium foil inner wrap with a lighter, single paper-based solution, while preserving the premium appearance and functional performance expected for chocolate products.

To meet these requirements, Amcor supported the transition to its AmFiber™ Performance Paper. The solution provides a recyclable* paper structure with barrier properties designed to protect chocolate against moisture and grease, both of which can affect product quality and shelf life. The redesigned packaging combines a natural kraft appearance with a matte finish, reinforcing Alter Eco’s brand positioning while meeting technical performance needs.

Addressing complex product characteristics
One of the redesigned chocolate variants contains whole almonds, which introduced additional technical constraints. The textured surface of the product required packaging capable of maintaining a smooth external appearance without compromising seal integrity or barrier performance. The AmFiber™ structure was adapted to meet these requirements, ensuring consistent visual quality across all three chocolate SKUs.

Measurable material and environmental gains
The redesigned packs achieve a significant reduction in packaging weight compared with the previous format. Depending on the product variant, the total packaging weight was reduced by between 37% and 61%. The new packaging can be recycled in the paper stream in France, provided appropriate collection and recycling infrastructure is available*.

The paper used is FSC^®-certified, confirming sourcing from responsibly managed forests, and the solution aligns with CEPI and 4evergreen recyclability guidelines. These factors support compliance with evolving European packaging and waste directives while reducing the overall material footprint.

Application relevance for food packaging
This development illustrates how paper-based packaging with enhanced barrier performance can be applied to demanding food applications such as chocolate, where sensitivity to moisture and fat migration traditionally limited fiber-based solutions. By combining material reduction with functional performance, the project demonstrates a practical pathway for brands seeking to replace multi-material packaging formats with recyclable paper-based alternatives.

* Recyclable in practice where paper recycling streams exist.
** Weight reduction compared with previous packaging: 37% for dark dessert chocolate; 61% for dark chocolate with whole hazelnuts and dark chocolate with whole almonds.

www.amcor.com