Mondelēz removes 2,200 tonnes of plastic from biscuit packaging
Paper trays replace plastic across 115 European biscuit lines
Mondelēz International has switched from rigid plastic to FSC-certified paper trays for more than 115 cookie products sold across Europe. The company says the change will remove roughly 2,200 tonnes of virgin plastic each year. This represents an 80% reduction in plastic use for affected packs.
The rollout covers eight brands sold in over 25 European markets. It forms part of Mondelēz's wider packaging commitments, which include cutting virgin plastic in rigid packaging by at least 25% and making all packaging recyclable by 2025. Consequently, this tray replacement is among the largest single packaging shifts the business has made in the region.
For UK businesses watching packaging regulation tighten, this move offers a clear example of how major manufacturers are reworking product formats to meet sustainability targets. Moreover, it shows that paper-based alternatives can be deployed at scale across high-volume consumer lines.
How the tray replacement fits wider packaging targets
Mondelēz operates under its "Snacking Made Right" sustainability strategy. This includes specific goals for 2025: a minimum 25% reduction in virgin plastic for rigid packaging and full recyclability across all packaging formats. The paper tray switch directly supports both objectives.
The company has already undertaken several packaging changes in Europe. In 2024, Mondelēz and Saica introduced mono-paper multipack packaging for LU biscuits in France, Belgium, and the UK. That move reduced virgin plastic by approximately 63% per pack, saving around 177 tonnes annually. Similarly, paper-based multipack bags for Cadbury biscuits in the UK cut virgin plastic use by roughly 145 tonnes.
These changes form a pattern. Mondelēz is systematically replacing hard-to-recycle plastics with fiber-based materials across its biscuit and snack ranges. The tray replacement is the largest intervention so far, but it builds on earlier trials and smaller rollouts. As a result, the company has tested the approach in multiple markets before committing to this scale.
Public reporting shows progress. Mondelēz's 2024 sustainability updates indicated that 96% of its packaging was designed to be recyclable, close to the 98% target set for 2025. However, progress on virgin plastic reduction can vary by market and product line. This underscores the difficulty of material substitution across diverse portfolios and geographies.
Why this matters for UK food manufacturers and suppliers
UK businesses face mounting pressure to reduce packaging waste. Extended Producer Responsibility for packaging comes into force in 2025, requiring businesses to pay the full net cost of managing their packaging waste. In addition, many retailers and public sector buyers now include packaging criteria in tender evaluations. Therefore, suppliers with lower-impact packaging formats gain a competitive edge.
Mondelēz's tray replacement demonstrates that large-scale substitution is technically feasible. The company has replaced rigid PET trays with FSC-certified paper across a high-volume product range without compromising shelf-ready formats. This matters for smaller businesses considering similar changes. If paper trays work for fast-moving biscuit lines across 25 markets, the format is likely robust enough for other food categories.
Furthermore, the switch affects supply chains. Packaging suppliers will need to offer paper-based alternatives that meet food safety, logistics, and shelf-life requirements. Businesses sourcing packaging should expect increased availability of certified paper formats as major brands shift demand. Meanwhile, recycling infrastructure must adapt to handle more fiber-based packaging, particularly where materials are combined with film or barrier layers.
There are also cost implications. Paper trays may carry different pricing than plastic equivalents, depending on volume, specification, and certification requirements. However, businesses can offset some costs through Extended Producer Responsibility fee modulation, which rewards recyclable and lower-impact materials. Companies should model both the upfront investment and the long-term savings when evaluating packaging changes.
Public procurement is another factor. Buyers increasingly require evidence of environmental performance, including packaging footprint. Suppliers to the NHS, local authorities, and central government departments must demonstrate progress on waste reduction to remain competitive. Consequently, businesses that adopt fiber-based packaging early may strengthen their position in public sector tenders.
Material reduction and recyclability in practice
The 2,200-tonne annual reduction is significant. To put this in context, it equates to removing the weight of roughly 1,100 average family cars in virgin plastic each year. This scale of change influences packaging norms across the snack sector and demonstrates the impact of switching a single component across a large product range.
FSC certification matters. The Forest Stewardship Council standard ensures that paper comes from responsibly managed forests. For businesses evaluating paper-based packaging, FSC or PEFC certification provides assurance that fiber sourcing meets environmental and social criteria. This is particularly important for companies with deforestation commitments or those reporting under science-based targets.
Recyclability depends on local infrastructure. Paper trays should be widely recyclable through kerbside collections in the UK, provided they are free from heavy contamination or laminated films. However, businesses must check how materials perform in real-world recycling streams. Some coatings or barrier treatments can complicate processing, so engaging with packaging suppliers and waste contractors early is essential.
Mondelēz has also experimented with recycled-plastic trays containing around 80% recycled content. This suggests the company is pursuing multiple material strategies rather than relying on a single solution. For UK businesses, this approach is instructive. A mix of recycled plastics and fiber-based alternatives may offer more flexibility than switching entirely to one material type.
What UK businesses should consider
- Mondelēz has replaced rigid plastic trays with FSC-certified paper trays across more than 115 European biscuit products, removing approximately 2,200 tonnes of virgin plastic annually.
- The change represents an 80% reduction in plastic use for affected packs and covers eight brands sold in over 25 European markets.
- The move supports Mondelēz's 2025 targets: a 25% reduction in virgin plastic for rigid packaging and full recyclability across all packaging formats.
- Paper-based alternatives are now being deployed at scale across high-volume consumer lines, demonstrating technical feasibility for food packaging.
- UK businesses should evaluate fiber-based packaging options in light of Extended Producer Responsibility requirements and increasing tender scrutiny on packaging waste.
Practical steps for packaging decisions
Businesses reviewing their own packaging should start with a material audit. Identify which components use virgin plastic, assess whether fiber-based or recycled alternatives are available, and calculate potential savings under Extended Producer Responsibility fee structures. This provides a clear baseline for decision-making.
Engage suppliers early. Packaging manufacturers are developing new formats in response to demand from major brands. Smaller businesses can benefit from these developments by asking suppliers about certified paper trays, recycled-content options, and barrier technologies that maintain product protection. Specifications should balance environmental performance with cost and functionality.
Test alternatives before committing. Paper-based packaging may behave differently in storage, transport, and display. Run trials with distribution partners and gather feedback from retail customers. This reduces the risk of operational problems after rollout. Additionally, ensure that new formats meet food safety and shelf-life requirements, particularly for moisture-sensitive products.
Consider certification requirements. FSC or PEFC certification adds credibility and meets expectations in public procurement and corporate supply chains. Check whether your sector or customer base prioritizes certified materials, and factor certification costs into your budgeting. Certification also supports reporting under frameworks such as the Carbon Disclosure Project or Streamlined Energy and Carbon Reporting.
Monitor regulatory developments. Extended Producer Responsibility for packaging will evolve, and fee structures may change to further incentivize recyclable and lower-impact materials. Stay informed about updates from the Department for Environment, Food and Rural Affairs to ensure your packaging strategy remains aligned with compliance requirements.
Our compliance support service helps businesses navigate packaging regulations, carbon reporting, and environmental standards. We work with suppliers to assess material options, model costs, and ensure that packaging changes align with both regulatory requirements and commercial objectives.
Where to find further guidance
The UK government's Extended Producer Responsibility guidance sets out reporting and payment obligations for businesses that supply packaged goods. This includes details on fee modulation and recycling targets. Additionally, the Waste and Resources Action Programme publishes detailed guidance on packaging recyclability and material selection for different product categories.
For businesses exploring certified paper options, the Forest Stewardship Council provides information on certification standards and supplier directories. The British Standards Institution also offers guidance on packaging sustainability and lifecycle assessment. These resources can help businesses compare material options and verify environmental claims.
Mondelēz's approach illustrates that large-scale packaging substitution is achievable with the right material sourcing and design process. UK businesses, particularly those in food manufacturing and supply, should assess whether similar changes could support their own sustainability targets while meeting regulatory and commercial expectations.