FREQUENTLY ASKED QUESTIONS
Why is chocolate packaging important?
Like all food and beverages, the chocolate industry is incredibly contested and requires a unique approach when trying to compete with the companies that have dominated the world for decades. The chocolate market in the UK alone is valued around £4 billion. It does not matter if your product is the best - no one will try your product if they are not convinced by the packaging, making it, arguably, more important than the chocolate itself.
Aside from customer attraction, chocolate packaging also needs to protect the product and keep it from the effects of heat or damage. Businesses are constantly seeking new ways to proactively protect their products whilst balancing their costs alongside it.
For those keen to explore the latest trends and technologies in chocolate packaging, the PPMA Show is one of the leading machinery exhibitions in the UK. Book a stand or register to gain vital industry knowledge and expertise.
What are the challenges of the chocolate packaging process?
Chocolate comes in a multitude of different shapes and sizes; from bars and larger tablets to individual chocolates, neapolitans and coins. Products are cut or moulded into squares, rectangles, balls, eggs, stars and other eye-catching forms in the search for consumer appeal and brand differentiation. With such a variety of chocolate products in the market, chocolate wrapping machinery is constantly being developed to meet ever more challenging demands.
In addition to the variety of products which chocolate wrapping machines are required to package, there are further challenges on hygiene, speed and accuracy. Chocolate also needs gentle handling in environments where the temperature is neither too high or too low, and where moisture levels are also controlled.
What is the chocolate packaging process?
The chocolate packaging process begins with a feed of the chocolate product from hoppers, drums, trays, belts or feeder tubes.
- The primary packaging process wraps the product in material such as aluminium foil, polymer films and coated papers or a combination of two materials. Single stage packaging wraps chocolates in a single operation using one or two materials. Double stage packaging wraps in two consecutive operations. The wrapping can be twisted, folded, glued or laser-sealed.
- Secondary packaging overwraps the product in materials such as cellophane, polypropylene films (including pouches), cardboard or paper or single item packaging or multipacks.
- Tertiary packaging procedures place the wrapped products in trays or cartons (including display cartons) which can be sealed in cellophane to protect the cartons from moisture or other damage.
- The final stage of packaging makes the products ready for dispatch in shipping cartons or on pallets.
What are the types of chocolate packaging machinery?
Chocolate packaging machinery comes as either stand-alone equipment or complete systems. The choice of system depends on speed and volume requirements, budget and type of product. Major producers prioritise efficiency and high output levels, while the growing artisan chocolate market concentrates on the final look of the packaging to support higher retail prices.
Chocolate products can be packaged by hand, but as with other products, hand working is slow, labour intensive and less accurate than machine-driven packaging. However, because there are no machinery investment costs, hand wrapping remains an option for very low volume artisanal chocolates produced for small food fairs or limited local distribution.
The next step up is to low speed machines, usually using a roll of foil for primary packaging and a stack of paper or board for folding around the product. Depending on the types of product being handled, flexibility can be important to allow for different sizes and shapes.
For high volume outputs, complete automatic or semi-automatic systems are required, including FFS (form, fill, seal) machinery. The elements in complete systems can comprise:
- Orientation systems for efficient feeding
- Flow and foil wrapping
- Vertical FFS machines for loose products in pouches and bags
- Horizontal FFS machines for bars and tablets
- PLC (programmable logic control)
- Filling and weighing equipment
- Buffering systems for feeding and loading
- Automatic loading systems
- Wraparound tray and carton packing
What is the best packaging for chocolate?
The best packaging for chocolate typically balances protection, presentation, and convenience, with options ranging from sealed bags for individual pieces to elegant folding cartons for boxed assortments. Shelf life, branding, and consumer preferences will also need to be considered. To name some examples, sealed bags or pouches are ideal for maintaining freshness and portion control, while rigid boxes add a touch of luxury for premium chocolates.
How important is automation for chocolate packaging?
Automation for chocolate packaging and its importance depends heavily on the scale of your operation. There are fair cases for using versus not using automation.
Chocolate products can be packaged by hand, but as with other products, hand working is slow, labour intensive and less accurate than machine-driven packaging. However, because there are no machinery investment costs, hand wrapping remains an option for very low volume artisanal chocolates produced for small food fairs or limited local distribution.
For larger operations, businesses can look at low speed machines, usually using a roll of foil for primary packaging and a stack of paper or board for folding around the product. Depending on the types of product being handled, flexibility can be important to allow for different sizes and shapes.
At the higher end, businesses will need complete automatic or semi-automatic systems, which is where automation shines. Machinery such as vertical FFS machines and horizontal FFS machines excel here.
What is the chocolate packaging process?
The chocolate packaging process begins with a feed of the chocolate product from hoppers, drums, trays, belts or feeder tubes.
- The primary packaging process wraps the product in material such as aluminium foil, polymer films and coated papers or a combination of two materials. Single stage packaging wraps chocolates in a single operation using one or two materials. Double stage packaging wraps in two consecutive operations. The wrapping can be twisted, folded, glued or laser-sealed.
- Secondary packaging overwraps the product in materials such as cellophane, polypropylene films (including pouches), cardboard or paper or single item packaging or multipacks.
- Tertiary packaging procedures place the wrapped products in trays or cartons (including display cartons) which can be sealed in cellophane to protect the cartons from moisture or other damage.
- The final stage of packaging makes the products ready for dispatch in shipping cartons or on pallets.
What are the challenges of the chocolate packaging process?
The chocolate industry faces many challenges when it comes to packaging, including:
- Maintaining product integrity in varying temperatures
- Ensuring proper sealing to prevent moisture and air exposure
- Preserving the aesthetic appeal of delicate chocolate shapes and designs
- Meeting strict food safety regulations and labelling requirements
- Balancing efficiency and speed while maintaining high-quality packaging standards