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Amcor, a global leader in responsible packaging solutions, has partnered with French organic snack producer Alter Eco to launch a new high-performance, fibre-based packaging format for the brand’s 200g chocolate bar range.

The redesign, executed in collaboration with Swiss co-packer HALBA, represents a significant sustainability milestone for the premium confectionery category. By transitioning to a paper-based solution, the partnership has achieved a packaging weight reduction of up to 61% while eliminating non-recyclable multi-material layers.

Material Innovation: AmFiber™ Performance Paper

The core of the new packaging architecture is Amcor’s AmFiber™ Performance Paper. This material is engineered to provide the high-barrier protection necessary for sensitive products like chocolate—specifically against water vapour and grease—without relying on traditional aluminium foil or plastic laminates.

Key Sustainability Metrics:

• Weight Reduction: The new format replaces the previous heavy cardboard sleeve and inner aluminium wrap with a single paper layer. This resulted in a 61% weight reduction for the hazelnut and almond SKUs, and a 37% reduction for the dark dessert chocolate variant.

• Recyclability: The packaging is fully recyclable within the French paper stream, aligning with CEPI and 4evergreen guidelines.

• Sourcing: The fibre used is FSC®-certified, ensuring responsible forestry management.

Preserving Premium Cues and Handling Texture

A critical challenge in the redesign was maintaining the premium aesthetic associated with the Alter Eco brand while accommodating complex product textures. One SKU containing whole almonds presented a specific hurdle due to its irregular surface. The AmFiber™ solution successfully maintained a smooth, high-quality appearance despite the textured product, preventing the "bumpy" look often associated with flexible paper wrappers.

The final design features a natural kraft look with a matte finish, reinforcing the brand's organic and authentic positioning on the shelf.

Janice Narainsamy, Senior Product Development Engineer at Amcor, highlighted the dual benefit of the material: “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.”

Anne Descarsin, R&D Pack Manager for Alter Eco, added: “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.”