Bel Group, a snack producer, is making a significant change to the packaging of its Babybel brand of individual wax-covered cheeses. The company is replacing the biobased plastic film introduced in 2020 with paper overwraps in an effort to enhance sustainability and reduce plastic usage. This transition is part of Bel’s broader sustainability initiatives aimed at producing a more recyclable pack and lowering carbon dioxide emissions.
The process of transitioning to paper overwraps has been in the works for five years, involving all five of Bel’s global production plants, including those in the United States. Delphine Chatelin, vice president of research, innovation, and development at Bel, stated that the shift to fiber packaging is expected to save 850 tons of plastic and 2,500 tons of CO2 annually.
Bel has already started rolling out the paper overwraps in the United Kingdom and plans to complete the transition in the United States, Canada, and Northern Europe by next year. The company aims to have the paper packaging available in all 50 global markets where Babybel is sold by 2027.
To successfully implement this packaging substrate change, Bel had to navigate the complexities and challenges associated with altering operations at its five production facilities. Selecting the right paper material and industrializing its use were key steps in the process. The company tested papers from various suppliers to ensure they met the necessary properties, such as barriers against oxygen and humidity, as well as aesthetic and tactile qualities for consumer experience.
Investing millions in each production line to accommodate paper substrates required adjustments to cutting tools, run speeds, and equipment upgrades. Maintaining production speeds while changing packaging materials and operations was a significant challenge, especially for factories producing millions of Babybel units daily.
After conducting lab validation and consumer testing, Bel began production at select factories to manufacture quantities for real-life testing in all countries where Babybel is sold. Consumers responded positively to the sustainability aspect of the recycled material and found the paper packaging easier to open compared to the plastic film.
The signature red wax that surrounds the cheese is an integral part of the product, aiding in ripening throughout the cheese’s life. While the wax provides some protection, the paper overwrap ensures the product’s overall protection during transportation and storage. Bel is also exploring paper packaging for direct food contact, as well as testing bulk options and reuse systems to reduce overall packaging volume in the market.
Bel’s commitment to sustainability extends beyond just packaging changes, as the company continues to explore innovative solutions to reduce environmental impact and enhance consumer experience. The transition to paper overwraps for Babybel is just one step in Bel’s ongoing journey towards a more sustainable future.
