How is Amcor Advancing Paper Packaging for Sustainability?

A collaboration between packaging manufacturer Amcor and organic food producer Alter Eco has resulted in the development of recyclable, paper-based packaging for chocolate bars destined for the French market.

The partnership demonstrates how manufacturing innovation can address sustainability challenges while maintaining product quality and premium presentation.

The project required Amcor to transition from traditional cardboard sleeve and aluminium foil wrap combinations to its AmFiber Performance Paper solution, working closely with HALBA, a Swiss chocolate specialist and co-packer, to ensure the manufacturing process could meet Alter Eco's requirements for reduced packaging weight without compromising the product's premium appearance.

Manufacturing recyclable packaging solutions

The manufacturing challenge centred on replacing existing packaging materials while maintaining protective properties and visual appeal.

Amcor's production team worked to develop a solution that could address a specific technical obstacle presented by one of the chocolate bars, where almonds created a textured surface that threatened to compromise the smooth, high-quality appearance Alter Eco required.

The manufacturing process for AmFiber Performance Paper needed to deliver effective protection against water vapour and grease while achieving significant weight reduction.

The final production solution resulted in packaging that is up to 61% lighter than the previous design and can be processed through France's paper recycling stream.

Janice Narainsamy, Senior Product Development Engineer at Amcor, says: "Paper-based packaging combines strong shelf appeal with a well-established perception of sustainability.

"With the right barrier performance, it can also deliver the protection needed for demanding applications like chocolate.

"Alter Eco's transition to AmFiber Performance Paper demonstrates this in a real market context, delivering a significant reduction in packaging weight."

Amcor's AmFiber product range, including the Performance Paper variant manufactured for Alter Eco's products, utilises various technologies to provide barrier protection, shelf life extension and machine performance across different product categories.

The production process incorporates engineering solutions designed to meet specific brand requirements while supporting sustainability objectives.

For manufacturers and brand owners, the technology offers potential benefits including recyclability and reduced material usage, alongside consumer-facing advantages such as natural aesthetics and ease of recycling.

Supporting sustainable manufacturing practices

Anne Descarsin, Research and Development (R&D) Pack Manager for Alter Eco, says: "This project illustrates our commitment to innovation, combining reduced environmental impact with uncompromising quality.

"Designing a thinner packaging that still protects the chocolate and preserves its organoleptic qualities is a true technical challenge and a major step forward for Alter Eco."

Alter Eco, established in France in 1998, produces organic and fairtrade food through partnerships with small-scale producers across 22 cooperatives in 18 countries.

The company's portfolio includes nearly 80 organic and fairtrade products across France, spanning coffee, chocolate, tea, cereals and spreads.

The manufacturing partnership with Amcor aligns with Alter Eco's broader operational goals, including its stated purpose of creating chocolate through thriving ecosystems with compostable packaging.

In 2024, the company reported a reduction in transportation emissions of more than 50% through strategic improvements in upstream and downstream logistics.

The company's supply chain strategy focuses on sustainable sourcing of high-quality cacao and supporting farming communities' long-term viability.

In 2024, 75% of Alter Eco's cacao beans came from dynamic agroforestry systems, reflecting its approach to building a resilient and regenerative supply chain.

The company has supported 573 farmers in transitioning to regenerative agriculture practices, with initiatives targeting soil health improvement, biodiversity enhancement and ecosystem resilience.