Cutting the Plastic: A Guide to Reducing Plastic Packaging in Baked Goods & Confections

For brand owners and manufacturers in the baked goods and confections space, limiting plastic packaging isn’t just a sustainability trend — it’s becoming a necessity. Consumers are demanding greener products, retailers are tightening their requirements, and regulations are increasing pressure to reduce single-use plastics. Whether you’re scaling a new brand or managing legacy SKUs, here’s how to start cutting down on plastic packaging without compromising product quality, shelf life, or shelf appeal.

1. Reassess Your Packaging Goals

Start by defining what “sustainability” means for your brand. Is your priority:

Reducing plastic weight per unit?
Eliminating plastic entirely?
Using recycled or compostable materials?
Meeting retailer or certification standards (e.g., FSC, How2Recycle, BPI)?

Having clear goals will help you evaluate materials and partners effectively.

2. Explore Alternative Packaging Materials

Here are some non-plastic options worth exploring:

Paper-based flow wraps and pouches: These can be lined with plant-based or water-soluble coatings to maintain freshness without relying on polyethylene.
Compostable films: PLA (polylactic acid) and cellulose-based films are heat-sealable and offer a transparent alternative to clear plastic bags, especially for individually wrapped cookies, bars, or caramels.
Molded fiber trays: Swap out PET trays for molded pulp inserts in multi-pack cookie boxes or chocolate assortments.
Glassine paper: A sleek, grease-resistant paper ideal for cookies, grahams, or brittle, especially for in-store bakery or DTC channels.

3. Lightweight What You Can’t Eliminate

If going fully plastic-free isn’t viable, reduce the amount you’re using:

Use thinner gauges of film where product protection allows.
Optimize your packaging size to eliminate headspace and reduce material usage.
Switch to mono-material plastics (like 100% PE or PP) to improve recyclability.

4. Rethink the Packaging Format

Sometimes the format is the problem:

Could a bag-in-box format replace a rigid clamshell?
Can you eliminate inner wraps and rely on a single exterior seal?
Is individual wrapping necessary for all channels, or can bulk packaging work for wholesale/D2C?

5. Use Recycled Content Wherever Possible

Look for packaging with post-consumer recycled (PCR) content — especially PET and paperboard. It doesn’t remove plastic entirely, but it reduces the footprint and aligns with sustainability goals.

6. Partner with the Right Vendors

Choose packaging suppliers who specialize in sustainable solutions. Some can co-develop new formats or have ready-to-run sustainable packaging that works on conventional lines — saving you from buying new equipment.

7. Test Early, Test Often

Shelf life, barrier properties, and machinability all matter. Start trials early to determine how alternative materials perform, especially with high-fat or sugar-based products (like brownies, brittle, or toffee) that can leach oils or react to humidity.

8. Educate and Engage Your Customers

Once you switch, tell the story. Use your packaging and website to explain the material choices you made and how customers can properly dispose of it. Consumers appreciate transparency and are more likely to support brands with clear environmental commitments.

Final Thoughts

Limiting plastic in baked goods and confections is a challenge — but it’s also an opportunity to build trust with eco-conscious shoppers, stay ahead of legislation, and future-proof your brand. Whether you’re making buttery cookies, chewy bars, or delicate chocolate truffles, there are smart ways to reduce plastic without sacrificing quality or performance.

If you’re looking to evaluate sustainable packaging options for your next confection or baked good line, I can help you explore what’s feasible based on your product type, target channels, and brand goals.