Introduction

A leading confectionery manufacturer was producing high volumes of a strongly flavoured seasonal product, creating a clearly identifiable surplus stream following peak production periods.

While established routes existed for managing the material through animal feed applications, the business wanted to explore whether more value could be retained by keeping suitable product within the human food chain.

The objective was to identify a practical reuse solution capable of handling distinctive flavour profiles while maintaining product quality and operational simplicity.

The Challenge

The surplus material presented both an opportunity and a complexity.

Its strong seasonal flavour profile limited traditional reuse options, meaning much of the product was being directed towards lower-value feed routes despite remaining suitable for food reformulation.

Any solution needed to:

  • retain food safety and product integrity
  • work effectively with distinctive flavour profiles
  • create a viable secondary food application
  • fit within existing operational processes
  • keep more edible product within the human food chain

The challenge was finding a reuse route where the flavour profile became an advantage rather than a limitation.

The ZRO Approach

Following extensive product trialling, ZRO identified an opportunity to incorporate the surplus confectionery material into the Choc Nibbles range through reformulation.

By adapting recipes and developing new pack formats, the strong flavour characteristics could be successfully integrated into secondary consumer products.

Working collaboratively across the wider ZRO system, the surplus product was redirected away from feed applications and retained within the food chain through structured reformulation pathways.

The result was a practical reuse solution that transformed a seasonal surplus stream into a usable food ingredient.

Implementation

The project included:

  • assessment of surplus product characteristics
  • reformulation trials using existing product ranges
  • development of suitable secondary applications
  • introduction of new pack formats
  • ongoing tracking through internal reporting systems

This enabled surplus confectionery product to be consistently recovered and repurposed within food production rather than being directed towards lower-value outlets.

The Results

Between September 2025 and December 2026:

More than 14 tonnes of confectionery product were retained within the human food chain

By redirecting surplus seasonal product into reformulation applications, the partnership helped reduce reliance on feed routes while creating new consumer product opportunities from existing output.

The Outcome

Reformulation created a higher-value outcome.

Using data-led analysis, the business identified a higher-value reuse pathway for white starch co-products — retaining more value from the same material while extending its use within the wider manufacturing economy.

When resources stay in use, value stays higher.

This project was delivered prior to the transition of Sweetdreams Ltd to ZRO Group Ltd in June 2026.