Cocoa Paper Moulds

Cocoa Paper Moulds / Source: Ecopack

AfricaAsiaCelluloseCocoa Paper MouldsCompostableEuropeFood & BeverageFood GradeFreezer SafeHeat ResistantLightweightMicrowave SafeNorth AmericaOil ResistantOven SafePackagingPaperRecyclableRegenerativeSouth AmericaUpcycled

WHAT WE SAY:

Cocoa bean shells are having their moment. Designers are exploring the humble husk's potential, from plant-based leather to thermo-acoustic panels. But there's a certain synergy about a chocolate cake wrapped in chocolate paper.

Ecopack's Cocoa Paper Moulds are a stylish food packaging alternative for baked goods, showcasing the raw and natural aesthetic of cocoa beans. Partially made using cellulosic fibres from discarded shells, which make up to 80% of the cocoa fruit's weight, the premium baking moulds transform the chocolate industry's waste and put it to use. With Ecopack's well-established manufacturing plants spanning five continents, the sky is the limit for Cocoa Paper Moulds.

Cocoa Paper Moulds

WHAT ARE COCOA PAPER MOULDS?

Cocoa Paper Moulds are an alternative baking Paper mould. They are made from a blend of Cellulose pulp and up to 40% virgin cellulose, derived from recycled cocoa shells, a secondary raw material. They are produced by Ecopack, an Italian supplier of food and confectionery packaging, with a specialism in baking moulds.
The paper is made using a patented "botanical reconstitution technology" that processes the fibres from cocoa bean shells, a raw by-product of the chocolate industry. The cocoa fibre goes through a refining process to produce pulp, which is then formed into sheets and dried.
Cocoa Paper Moulds are unprinted, maintaining a raw and natural aesthetic and texture. They feature a water-based adhesive for lamination, and use no chemicals or additive inks in their production. They are also PFOA and PFOS free.
According to the company's UK distributor, Ecopack manufactures its Cocoa Paper Moulds in Italy, sourcing cocoa fibre waste from local chocolate factories.
Ecopack's Cocoa Paper Moulds are greaseproof and oven, microwave, and freezer safe, withstanding a temperature range from minus 40 up to 220 degrees celsius. They are also free standing, with enough structural integrity to be placed directly in the oven without the need for a baking or muffin tray to stabilise them.
Ecopack's Cocoa Paper Moulds range includes pie and loaf moulds; tulip and lotus cups; muffin and cupcake cups; and muffin trays. Each product type is available in a range of sizes, and a weight range of 40 to 350 grams per square metre.
Cocoa Paper Moulds are 100% compostable, breaking back down into soil after use, with a home compostability certificate from TUV Austria. They are also recyclable and can be disposed of in paper and organic waste streams.
Cocoa Paper Moulds are available worldwide through Ecopack's regional offices, and select items can be purchased through Amazon.

KEY PROPERTIES:

Compostable
Food Grade
Freezer Safe
Heat Resistant
Lightweight
Microwave Safe
Oil Resistant
Oven Safe
Recyclable
Regenerative
Upcycled

INDUSTRY:

Food & Beverage
Packaging

AVAILABILITY:

Mass Market

DIVE DEEPER:

It's estimated that up to 70% of the entire cocoa plant is "considered waste and leftover by-product", according to global supplier Meridian Cocoa.
The International Cocoa Organisation (ICCO) puts yearly global cocoa production at around five million tonnes. But given that every tonne of harvested cocoa beans generates ten tonnes of cocoa pod husks, there is huge potential for the vast volumes of this raw waste material to be upcycled into something of value.
As part of its commitment to sustainability, Ecopack states that its Cocoa Paper Moulds support the EU Action Plan for the Circular Economy, adding value to the chocolate industry's waste stream. It also claims that they have a reduced carbon footprint, consuming less energy and resources thanks to its automated manufacturing lines.
Proceeds from Ecopack's Cocoa Paper Moulds are used to support the Jacundá Forestry REDD+ Project in Brazil, enabling local communities to minimise deforestation and soil erosion; improve water quality; and monitor threatened species of birds and primates. The preservation project is validated by the Rainforest Alliance, and is projected to save over seven million tonnes of CO2 over its 30-year duration.
The company's product catalogue features over 800 items, predominantly made from FSC-certified virgin paper, while Cocoa Paper Moulds were introduced in 2018. The company also has a savoury line, which includes pie moulds, salad bowls, and takeout food containers made from a blend of paper and Bamboo fibres. It also offers made-to-fit lids with some of its containers, which are made from recycled PET.

Ecopack has established a global manufacturing and distribution network spanning five continents. Headquartered in Italy, it has production plants in Tunisia, Brazil, Canada, Russia, and India.

A pie mould made from Cocoa Paper / Source: Ecopack

Cocoa Paper features cellulosic fibres from cocoa bean shells / Source: Ecopack

KEY FACTS:

70%

Up to 70% of the entire cocoa plant is considered waste and leftover by-product

800

Ecopack's portfolio includes over 800 items

5mn tns

Global cocoa production sits at around five million tonnes per year

Key Questions to Ask:

Where are Cocoa Paper Moulds available?

Cocoa Paper Moulds are available in the UK via Ecopack's distributor, Greenearth Food Packaging. According to the company's websites, the moulds are manufactured in Ecopack's Italian and Tunisian plants. However, if you are based elsewhere, it'd be worth exploring whether your region's Ecopack production site can source a domestic supply of cocoa shells to save on carbon emissions and bolster the local economy.

What other food packaging products could be made from Cocoa Paper?

Admittedly, Ecopack's Cocoa Paper Moulds are just one very specific use of Cocoa Paper. However, the company could easily expand its range to include items such as food wrapping paper for takeout sandwiches, or paper sheets and boxes for confectionery packaging. Ecopack offers customisable options and services, so it'd be worth speaking to your local branch if you have a novel idea for incorporating Cocoa Paper into your packaging.

What other uses does cocoa plant waste have?

Cocoa Paper Moulds are a commercially available and scalable upcycling solution for cocoa bean waste. Yet there are a number of experimental projects exploring innovative ways to harness the versatility of this high-value raw material. Take Lakò Studio, an Italian-Ecuadorian team of designers using biotechnology to develop sustainable materials using cocoa industry waste, such as Kajkao, a line of building materials. Other use cases include cocoa shell tea; an alternative livestock feed; and a source of biofuel in Ghana, the world's second largest producer of cocoa. Fuelling homes and our sugar cravings seems like just the beginning for this humble husk.