Luxury Chocolate Packaging Manufacturing
We produce custom thermoformed packaging for premium chocolate brands, confectioners, and artisan chocolatiers. Our packaging solutions include individual chocolate blisters, box inserts (cavity trays), clamshell display packaging, and protective transit trays—all in food-contact certified materials.
Materials & Food Safety
All packaging is produced in virgin PET or rPET (recycled PET) certified for direct food contact per EU 10/2011 and FDA 21 CFR 177.1630. PET offers excellent clarity (>90% transparency) for product visibility, odour neutrality critical for chocolate, and full recyclability.
For premium presentations, we offer gold/silver metallised PET, soft-touch coated PET, and anti-fog treated PET for refrigerated displays.
Thermoforming Process
Our vacuum and pressure thermoforming lines produce packaging from 0.2mm to 1.5mm thick PET sheet. Pressure forming achieves sharper cavity definition critical for individual chocolate pockets that hold each piece securely during transport.
Tooling is CNC-machined aluminium, costing 70-80% less than injection moulds while offering 500,000+ cycle life. New designs are prototyped in 48 hours for fitting trials with actual chocolates.
Customisation
Each tray is custom-designed to match your chocolate shapes and box dimensions. Our CAD team works from chocolate samples or 3D models to create pocket geometries with optimal clearance—snug enough to prevent movement, loose enough for easy extraction.
Quality & Sustainability
ISO 9001:2015 and BRC/IoP certified for food packaging. We offer 100% rPET (post-consumer recycled) trays meeting the same performance standards as virgin material. Carbon footprint calculations available for sustainability reporting.
Frequently Asked Questions
What is the minimum order for custom chocolate trays?
Prototype tooling available from 100 pieces for fitting trials. Production tooling minimum: 5,000 trays. Stock tray formats (4, 6, 9, 12, 16, 24 cavities) available from 500 pieces.
Can trays be produced in recycled material?
Yes, we offer 100% rPET trays with identical clarity and food safety certification. The rPET option adds approximately 5-8% to material cost but eliminates virgin plastic use entirely.
Technical Specifications
Material: PET / rPET (EU 10/2011, FDA) | Thickness: 0.2-1.5mm | Process: vacuum & pressure forming | Tooling: CNC aluminium | Formats: 4 to 48 cavities | Certifications: ISO 9001, BRC/IoP