Chocolate bar manufacturers turn to die-fold, hermetically sealed single-wraps

‘Die-fold packages were avoided in certain markets because it was difficult to achieve airtight sealing’

By Jenny Eagle

- Last updated on GMT

Chocolate Bosch hermetically sealed single-wraps

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Manufacturers who previously relied on sealed aluminum foil or flow pack for chocolate bars can now use OPP hermetically folded and sealed die-fold packaging, according to Sapal, a Bosch Packaging Technology company.

It claims Bosch’s BVK 1300 PT and DSD 0600 H technology both use hermetic sealing. The first one can switch between double-twist, hermetical double-twist and flow wrap packaging with up to 1,000 wraps per minute whereas the second produces up to 600 airtight die-fold hermetic seal wraps.

Moisture, dust and insects

According to Bosch, hermetic sealing is airtight and tamper-proof, safeguarding products from moisture, dust and insects and increases machine flexibility by switching from flow wrap to double-twist wrapping styles.

Martial Menoud, head of technical and commercial sales support centre, Sapal, told FoodProductionDaily, for consumers, chocolate is an indulgence and packaging is a gateway to this luxurious treat.

For chocolate manufacturers who want to give their products the competitive edge, die-fold packaging has traditionally been the wrapping style of choice thanks to its premium look​,” he said.

But while it was praised for its visual presentation, die-fold packages were avoided in certain markets because it was difficult to achieve an airtight sealing. If a single layer is used, dust, aromas or insects could penetrate the packaging and affect product quality, especially in countries with hot and humid climates​.”

Menoud added, for example, India’s chocolate market is projected to grow by 18% from 2014 to 2019, after the average consumption of chocolates tripled to 120g per capita between 2008 and 2013, according to TechSci Research.

In South Africa, industry experts are witnessing double-digit growth rate figures and a surging demand for high-quality, premium chocolate products (Frost & Sullivan: ‘A sweet future for the South African chocolate market’ report 2013).

Food safety issues

Using the most protective packaging will help manufacturers capitalize on these market opportunities​.” said Menoud.

After a number of highly-publicized food safety issues, including in several central European countries and China, product integrity and safety has become more vital than ever​.

As consumer rights organizations and governmental institutions keep a close eye on food security issues, chocolate manufacturers are making product safety one of their main priorities. Packaging is one of the tools they use to protect their products and brands​.”

He said manufacturers can now incorporate wrapping technologies that create an aesthetically pleasing appearance without additional material usage and costs.

Modern packaging machines use a folding box to create all folds at the same time. This results in symmetrical sides and longitudinal seals, ensuring packaging with high seal integrity​,” added Menoud.

Because the global demand for premium chocolate is projected to continue to rise for several years (MarketsandMarkets, Feb. 2010), these wrapping options offer growth opportunities for chocolate producers in current and new markets​.

Chocolate Confectionery in Russia

According to ‘Chocolate Confectionery in Russia’ by EuroMonitor March 2014, Russia is witnessing a premiumization trend and Russians will continue to treat themselves with premium chocolates in spite of slowing economic indicators.

The competitive chocolate market means manufacturers need to have a wide product portfolio and a versatile production process. They need to regularly switch between different products, such as for seasonal or promotional campaigns​,” said Menoud.

New packaging technology enables manufacturers to choose between different refined wrapping styles such as a flow wrap and two end-fold wrapping styles – double-twist and hermetical double-twist – on the same machine​.

Another flexible packaging option allows manufacturers to switch hermetic sealing on and off, allowing manufacturers to keep up with changing retailer and consumer demands while optimizing production footprint​.”

He added, while meeting market demands for product safety and flexibility, chocolate producers are often struggling to maintain a healthy bottom line and need packaging equipment with a lower total cost of ownership (TCO).

Ultrasonic sealing allows manufacturers to employ a number of materials without patent constraints, reducing costs. Moreover, the wrapping material used for ultrasonic sealing is less sensitive to storage and transport conditions, reducing waste and providing additional savings potential​,” he said.

By switching between conventional die-fold wrapping and hermetic sealing on the same machine, chocolate producers avoid unnecessary spending​.

For the conventional single-wrap die-fold packaging paper material is folded around the product and retained in place by a glue drop. Whenever die-fold hermetic sealing is applied, oriented polypropylene (OPP) is heat sealed. An option to switch hermetic sealing on and off allows manufacturers to use eco-friendly and cost-effective materials whenever possible​.”

Sapal is exhibiting at ProSweets in Cologne, Germany, from February 1-4 and Bosch will be presenting a session at ProSweets Speaker’s Corner on February 3 between 2-3pm in Hall 10.1 stand A-071/B-079.

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