Moulding tomorrow’s chocolate

July 24, 2024

From cocoa suppliers to equipment manufacturers and chocolatiers, a unifying theme moulding the realm of chocolate innovation: future-proofing. Exploring the key innovations and strategies that are reshaping the future of chocolate globally, we look into how ensuring sustainable business growth and market relevance is an emerging trend in chocolate.

Embracing packaging technology: Shaping the future of chocolate

In the rapidly evolving realm of chocolate innovation, various stakeholders—from ingredient suppliers to machinery manufacturers and producers—collaborate with a shared objective: gearing up for the future through cutting-edge packaging technologies. As consumer demand shifts towards greater customisation and personalisation, innovative packaging emerges as a pivotal tool. It allows chocolate to be tailored to individual preferences without compromising the consistency or original recipe of confectionery products. This strategic approach not only enhances customer satisfaction but also enables manufacturers and producers to streamline operations, reducing the need for extensive product development cycles.

Companies at the forefront of this technological evolution include Barry Callebaut, known for its sustainable practices and innovative packaging solutions. Barry Callebaut implemented a state-of-the-art packaging system at its Eddystone, PA facility, ensuring optimal protection and stability for cocoa powder during transport and storage. Facing the challenge of efficiently handling cocoa-filled paper bags stacked on pallets of varying sizes (Euro and GMA standards), Barry Callebaut turned to BEUMER Corporation for a tailored solution. The collaboration resulted in the installation of a comprehensive packaging line featuring BEUMER’s Integra bagging system, designed for high-speed and precise filling and sealing of bags. This system integrates quality control measures like metal detection and checkweighing to ensure product integrity.

Post-bagging, BEUMER’s automated palletising and stack press technologies enhance stack stability by removing residual air from the bags. A pivotal component of the solution is the BEUMER stretch hood, which wraps a protective film around the palletised bag stacks. This innovative hooding system not only shields the cocoa powder from environmental elements like wind, rain, and dust but also enhances stack visibility and stability. By applying constant tension force, the stretch hood accommodates variations in bag volume due to settling, optimising film consumption and reducing material costs by up to ten percent. Since the modernisation, Barry Callebaut has experienced simplified operations with enhanced product protection and reduced environmental impact. The integration of advanced packaging technologies not only meets stringent safety requirements but also aligns with Barry Callebaut’s commitment to sustainability, marking a significant stride towards more efficient and eco-friendly operations in the cocoa and chocolate industry.

Another notable entity is Calico Confectionery, renowned for pioneering advancements in chocolate manufacturing machinery and packaging systems, ensuring efficiency and product integrity. In 2018, Calico Confectionery launched their range of compostable packaging that breaks down and dissolves in soil. Made using sustainably sourced trees, the raw materials are converted into a pulp, which is then made into a transparent solid film which then gets coated and cut to size. The change came when managing director Nigel Baker watched David Attenborough documentary ‘Blue Planet’. Upon seeing the effects of single-use plastic in the oceans, Baker committed to moving away from single-use plastic in 2017.

These companies exemplify how forward-thinking approaches to packaging can revolutionise the chocolate industry, meeting consumer expectations while optimising production processes.

Read the full feature in our magazine.