The Real Sweet Spot: Chocolate Alternatives + Smarter Flexible Packaging
Cocoa prices recently hit a 60-year high—and it’s no short-term spike (Eastlake, 2025). With Ghana and Ivory Coast supplying over 60% of the world’s cocoa, recent crop losses caused by extreme weather, aging trees, and disease have raised serious concerns about long-term supply and sustainable sourcing. For confectionery brands, that means one thing: adapt to this new reality or risk falling behind.
This goes beyond reformulating ingredients; it requires making responsible choices that reflect consumer values. The flexible packaging that carries these products will be just as crucial to success in these new market conditions. In a crowded snack aisle, it’s often the first—and most lasting—impression.
New Bars, New Beginnings
In response to price pressures and long-term instability, a wave of chocolate alternatives is gaining momentum. Some innovators are bypassing cocoa altogether. Voyage Foods, for example, has introduced a cocoa-free chocolate made from ingredients like grape seeds, sunflower protein, and palm kernel oil.
This surge in innovation isn’t just driven by cost. Many of these alternatives tout additional benefits: more stable supply chains, lower carbon footprints, and new sourcing models that reduce reliance on vulnerable agricultural regions.
Why it Matters: A New Bar For Sustainability
The shift toward cocoa alternatives reflects more than a supply-side correction. It’s part of a broader transformation in how brands source, produce, and package consumer goods. Today’s consumers increasingly associate brand values with environmental impact—and packaging plays a visible, tangible role in shaping perception.
In fact, 82% of global consumers say they’re willing to pay more for products with sustainable packaging, with that number climbing to 90% among Gen Z shoppers.
The regulatory landscape is also shifting. U.S. Extended Producer Responsibility (EPR) laws are changing the way producers manage the environmental impact of their packaging by assigning financial responsibility for recycling. It encourages more thoughtful choices across packaging materials based on recyclability and overall impact.
What Brands Can Do Now
Cocoa alternatives solve one piece of the sustainability puzzle—but packaging plays an equally vital role. That’s why the next generation of coated paper packaging is gaining traction, especially for products like chocolate bars, pretzels, and snack chips. As brands explore options beyond conventional materials, these solutions not only meet performance needs, but also offer a compelling way to strengthen their sustainability story.
Coated paper formats can be recycled curbside and even compostable in some markets—without compromising on performance or food safety. They offer comparable properties to polyolefin packaging materials, including oxygen and grease resistance, making them viable for high-fat and high-sugar applications like candy.
The Sweet Spot For Sustainable Snacking
As the cocoa supply chain evolves, so do consumer expectations. Chocolate innovation isn’t just about better ingredients—it’s about delivering a unified experience that reflects brand values from start to finish.
From lab-grown cocoa to barrier-coated paper, today's most forward-thinking brands are pairing ingredient innovation with recyclable, repulpable packaging that’s easier to dispose of and harder to ignore. For conscious consumers, that kind of end-to-end integrity isn’t just a bonus—it’s the expectation.
Looking to bring your next bar to market? Let’s talk about how smarter flexible packaging—from barrier-coated paper to compostable films—can help you tell a more consistent, credible, and delicious story. Connect with a Pregis blown films representative to get started.
Eastlake, D. (2025, June 11). Cocoa prices plunge following record highs. FoodNavigator.com. https://www.foodnavigator.com/Article/2025/06/11/cocoa-prices-fall-following-record-highs/
