PACKAGING TRENDS
ethylene.
This renewable by-product of normal sugarcane production is ethically cultivated and fully recyclable, yet delivers the required optics and high shrinkage to ensure a well-protected and well-presented pizza. After successful film trials of the material on The White Rabbit’s existing shrink-wrapping lines, the company placed its first order for film. By switching to B-NAT from traditional polymer shrink films, the company has calculated that it will save around 18,700kg of CO2 emissions each year. Commenting on the solution, Matteo Ferrari, Co-Founder at The White Rabbit Pizza Co says: “We are always looking for ways to make our packaging more environmentally friendly. We use cardboard pizza discs instead of polystyrene and fully recyclable cardboard boxes, so the sugarcane plastic is totally in keeping with our ethos and mission to be greener.”
From tubs to flow-wrap Fitbakes started life in founder Ella Rauen- Prestes’ kitchen in 2018 as round, low sugar, high protein, reduced calorie bite-sized cakes packaged in a tub with lidding film and a cardboard sleeve. Due to the success of the product, Fitbakes production needed to be moved to a third-party baking and packaging facility. At the time of the move, Fitbakes changed the cake format from round pieces to square cakes so the company also needed to consider new packaging options.
Fitbakes spoke to Constantia FFP to help it develop a sustainable packaging solution that would portray a natural, yet premium look and feel and would be robust and durable enough to withstand the logistics supply chain while giving the product at least 30 days shelf-life. As the products were sold online and in supermarkets, they needed to be easy to merchandise and branding needed to be consistent and vibrant for shelf appeal. The cakes were going to be packaged as a four- pack, with six flavour offerings. FFP was able to develop a flow wrap solution made of paper, laminated to a pearlised orientated polypropylene (OPP), a type of plastic film that is stretched in one direction, so the microscopic fibres are aligned. This helps with strength and creates a clear plastic film. The paper outer gives the product the desired natural premium look, while the OPP layer has eliminated any product show-through. It has also offered enhanced durability and ensures a long shelf-life. By moving to a flow wrap solution from a tub, lidding film and sleeve
28 Kennedy’s Bakery Production April/May 2024
solution, Fitbakes has significantly improved its offering on both an environmental and commercial level. Commenting on the project, Ella Rauen-Prestes says: “Moving our production to a third-party, was a huge milestone for us and a reflection of the success of the brand in the marketplace. Finding the right packaging partner to develop a solution that provided the functionality we required while maintaining the brand’s integrity was paramount. The change has also enabled us to streamline our processes and strengthen our sustainable credentials.” Moving to an automated packaging process has also made the packaging process faster, less labour intensive and ultimately more efficient. This, along with the overall reduction in the volume of packaging required, means the new packs are more economical to produce and Fitbakes now has the capability and capacity to produce larger volumes to meet consumer demand. The company also identified an opportunity within the growing food-to-go market sector for a smaller ‘twin-pack’ product. The smaller pack format would be merchandised easily on-shelf and provide consumers with a guilt free snacking option that could be eaten on- the-go. The packaging that FFP had produced for the four-pack, lent itself well to the new project and was easily scaled down in size to accommodate the new ‘twin-pack’ offering.
Paper for chocolate bar packaging The latest chocolate bars from Leipzig-based chocolate manufacturer, nucao are not only organic, vegan, and fair trade, they also use 100% paper packaging after teaming up with
Koehler Paper. Nucao has always taken a 360° sustainability approach to its chocolate bars. It not only advocates for a deforestation-free supply chain and fair remuneration for cocoa farmer families, but it is also taking a stand in the fight against plastic waste by moving eco-friendly packaging. Mathias Tholey, Co-Founder at nucao, says: “Many chocolate manufacturers focus on one green attribute, but fair trade, organic, or vegan alone is not enough to ensure your business is truly sustainable today. You need the full package!” The Koehler NexPlus Advanced flexible packaging paper is able to provide protection for the chocolate thanks to its oxygen, mineral oil, and grease barrier properties. When developing this flexible packaging
paper, the focus was on making it recyclable while ensuring it also offered suitable product protection. As a result, the paper can be recycled as part of a standard paper recycling process and can often be reused. This is also certified by the Papiertechnische Stiftung (PTS, Paper Technology Foundation) and environmental service provider Interseroh.”
There can be no doubting the need for bakeries to review their packaging options. Today packaging material providers are able to offer many more ‘sustainable’ solutions. It may cost a bit more, but reports show that consumers are willing to pay more for environmentally- friendly options today. Whichever route is taken; however, it is important to ensure that existing packaging equipment is able to work efficiently with any new materials chosen.
bakeryproduction.co.uk
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