From best seller in a jar to single-serving in a bag or airplane: the story of the packaging that transformed a Calabrian excellence into an even more accessible, safe and modern product.

There is something unmistakable about Calabrian chili: the intense aroma, the lingering heat, and the strong character that can turn even the simplest dish into an experience. TuttoCalabria has been synonymous with this authenticity for years-an Italian food company with deep roots in Calabria and a catalog that has become a benchmark for lovers of quality hot pepper. When it decided to launch into the world of single-servings, it chose Encanto as its co-packing partner. The result is a product line that literally flies on planes today.

TuttoCalabria: a leader in Calabrian chili

TuttoCalabria’s core business is clear and well-defined: production of hot sauces and seasonings made from Calabrian chili peppers, grown in an area – Calabria – where the warm Mediterranean climate and nutrient-rich soils give rise to chili peppers with a truly inimitable taste. The company has established itself as an industry leader, building a reputation based on the quality of raw materials, respect for tradition and attention to production processes.

Among its most beloved products is chopped chili pepper: a versatile condiment capable of enhancing any preparation with characteristic Calabrian ardor. And it was around this product that the idea of the single-serving was born.

5 Sachets Set
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Sachet Single-dose
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Doypack paper based
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5 Sachets Set
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Sachet Single-dose
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Doypack paper based
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5 Sachets Set
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Sachet Single-dose
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Doypack paper based
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The idea: from jar to on-the-go

The spark that gave birth to the project came from a specific request: an airline needed a single-serving version of chilli chunks that would be compatible with in-flight service requirements-practical, safe, leak-proof, and easily manageable. A brief that sounds like a nontrivial technical challenge, especially for a product like chili oil, which is notoriously difficult to contain without risk of spillage.

TuttoCalabria’s response was to look for a Co-packing partner that was up to the task. The choice fell on Encanto, not by chance: “We chose Encanto because of the reliability and seriousness with which it approaches the world of Co-packing,” they explain from the company, emphasizing how the selection of partners follows a strict checklist that includes corporate reputation, quality certifications, operational transparency and on-time delivery.

“The collaboration stems from the desire to offer our product in a mode never before proposed: single-serve. The need was to develop packaging that was functional, durable and, above all, oil-proof.” – TuttoCalabria

Doypack
Sachet
Sachet e Doypack Single-Dose

Two products, two packaging solutions

Chili Pepper Pieces in Single Dose Sachet 3-side, 10g

For chilli chunks, Encanto has created a single-sided sachet sealed on three sides-a format achieved by folding and heat-sealing a laminated sheet with a high barrier against moisture, light, and oxygen. The three-sided sealing provides superior structural strength-thanks to the folded base that offers more support-and minimizes the number of seam points, increasing the reliability of the closure. The result is a 10g sachet that also arrives in a 5-pack, ideal for retail or foodservice use.

Calabrian chili oil in paper-based Doypack, 10ml

The most complex technical challenge involved chili oil: a liquid product with intense odors and physical characteristics that challenge any packaging system. The solution is Encanto’s paper-based Doypack, a multilayer packaging consisting of 100% certified FSC™ virgin fiber, a thin layer of 12 μm aluminum for maximum protective barrier against oxygen and light, and a PE film. This material effectively prevents the escape of intense odors-a feature also valued for nutraceutical or herbal products-ensuring the integrity of the oil from production to consumption.

Two products, two packaging solutions

Chili Pepper Pieces in Single Dose Sachet 3-side, 10g

For chilli chunks, Encanto has created a single-sided sachet sealed on three sides-a format achieved by folding and heat-sealing a laminated sheet with a high barrier against moisture, light, and oxygen. The three-sided sealing provides superior structural strength-thanks to the folded base that offers more support-and minimizes the number of seam points, increasing the reliability of the closure. The result is a 10g sachet that also arrives in a 5-pack, ideal for retail or foodservice use.

Calabrian chili oil in paper-based Doypack, 10ml

The most complex technical challenge involved chili oil: a liquid product with intense odors and physical characteristics that challenge any packaging system. The solution is Encanto’s paper-based Doypack, a multilayer packaging consisting of 100% certified FSC™ virgin fiber, a thin layer of 12 μm aluminum for maximum protective barrier against oxygen and light, and a PE film. This material effectively prevents the escape of intense odors-a feature also valued for nutraceutical or herbal products-ensuring the integrity of the oil from production to consumption.

From the sky to retail: a project that has taken off

Created to meet a specific demand from the airline industry, the TuttoCalabria single-serve quickly proved to have much broader potential. The quality of the product and successful packaging prompted the company to expand distribution, finding new contexts for consumption-from catering to hospitality to specialty retail.

It is confirmation of a principle that applies to many food excellences: carefully thought-out packaging is not just a logistical solution, but an amplifier of product value. The single-serving did not make TuttoCalabria smaller-it made it more accessible, without ever betraying the Calabrian soul of the product.

The value of tailored co-packing

The TuttoCalabria project is an emblematic example of Co-packing understood as a strategic partnership, not as a simple packaging service. The collaboration with Encanto made it possible to develop a packaging solution that did not exist on the market in the required form, meeting demanding quality standards and opening up new distribution channels. When the right partner is there, even the most complex technical challenge becomes an opportunity.

Chili Calabrese Co-Marketing Co-Packing Doypack Food Packaging Made in Italy Single-dose