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Mars Wrigley Develops, Tests Paper-based Packaging for Balisto Chocolate Bar

As brands eye fast-approaching, self-imposed sustainability deadlines, watch for interesting pilot projects to roll out. This European paper-based flow pack from Mars Wrigley's Balisto brand of snacks was developed with Syntegon.

The Honey Almond bar hits shelves in a paper-based flow wrap packaged on Syntegon’s HRM horizontal form-fill-seal machine.
The Honey Almond bar hits shelves in a paper-based flow wrap packaged on Syntegon’s HRM horizontal form-fill-seal machine.

Flow-wrapped film packaging once was the format of choice for confectionery, especially chocolate bars. To a great extent it still is, but times are changing, and so is the material that candy bars are wrapped in. Consumer goods companies are looking for more sustainable materials. For example, just a few weeks ago, Packaging World covered Nestle’s ‘paperization’ of its popular Smarties line of candies. The crunchy snack is packaged in all-paper multipacks at nine bars each.The crunchy snack is packaged in all-paper multipacks at nine bars each.

Under the same types of pressures, Mars Wrigley is concurrently investigating the flow-wrapping potential of paper. These major brands are all actively searching for more sustainable packaging alternatives in order to meet self-imposed sustainability goals. For example, as a major Mars business segment next to Petcare and Food, Mars Wrigley is aligned with the Mars Corporate Sustainability Vision to a Healthier Planet. Mars is a core partner of the Ellen MacArthur Foundation’s (EMF) New Plastic Economy initiative, and one of the first signatories of the EMF’s Global Commitment to eliminate plastic waste and pollution at its source. The Mars Vision is aligned with EMF to support a circular economy where packaging never becomes waste. To make this vision a reality, by 2025 Mars plans to reduce virgin plastic use by 25% and ensure 100% of its plastic packaging is reusable, recyclable, or compostable.

Beta Testing Paper Packaging

So wSyntegon TechnologyThe flat, chocolate-covered cookie snack bar is offered in a range of flavor variants and colorful packaging.

Where less established materials are at play, Mars Wrigley recognizes that suitable packaging materials need to be developed and tested regarding machine performance criteria and market acceptance. “As challenging as this process can be, we wanted to go the extra mile to deliver on our sustainability commitment and our commitment to quality,” says Gerben Santegoeds, Global Technology Principal Engineer Packaging at Mars Wrigley.


Read article   The Mars Wrigley paper-based flow wrapped project with Balisto is yet another example of brands testing paper where flexible plastic film once dominated. Here's another from a recent issue of Packaging World: Nestlé Achieves ‘Paperization’ of Confectionery Packaging


The company has already launched several pilot projects across Europe. The valuable insights gained from these pilots can then be harnessed to develop sustainable packaging solutions in all categories of Mars Wrigley’s portfolio. One of the pilots now underway at Balisto® is the Honey Almond flavor chocolate bar. In line with the company’s vision to use more recyclable material, the bar is currently being packaged in a paper-based flow wrap for validation purposes. For this solution to become a reality, Mars Wrigley had to develop and test a paper-based flow wrap for single bars and multipacks.

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