SFA Packaging Develops Sustainable Molded Fiber Inlay For Tony’s Chocolonely Advent Calendar

SFA Packaging has created an innovative sustainable molded fiber (paper pulp) inlay for the Tony’s Chocolonely Advent calendar, supporting the brand's goal of transitioning to a fully mono-material packaging format. This new inlay is designed to be processed in the same recycling stream as the cardboard outer box, aligning with European 2030 PPWR guidelines.

The project addresses the challenge of combining cardboard outer boxes with plastic inlays, which complicates recycling. By using molded fiber, SFA Packaging has simplified this by creating a mono-material solution that allows both components to be recycled together.

Developing the inlay required precision, as each cavity had to match the exact positioning of chocolates behind the calendar’s doors. Despite challenges posed by the discharge angle in molded fiber production, SFA Packaging succeeded after several iterations and prototypes, balancing sturdiness and fit for both large and small formats of the Advent calendar.

The new inlay design also improved packing efficiency. It is easier to fill and insert into the outer box, resulting in a faster packing process with fewer manual steps. This not only improves speed and stability but also enhances the overall efficiency of the co-packer.

The partnership between Tony’s Chocolonely and SFA Packaging has proven fruitful. Laura van Veen, Purchaser at Tony’s Chocolonely, praised the team for their flexibility and commitment to improving packaging sustainability. She expressed optimism for future collaboration to build upon this success.

SFA Packaging has a history of developing sustainable packaging solutions. With this molded fiber innovation, they now offer customers a choice between plastic and fiber-based alternatives, both with 100% recyclability. The company continues to meet the growing market demand for eco-friendly materials, contributing to a circular material flow in packaging.