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Nestlé has moved to make this winter's Christmas selection boxes totally recyclable by replacing plastic inserts with a paper-based alternative.

In a change that is designed to build on lightweighting initiatives carried out last year, Nestlé plans to remove plastic inserts from its selection boxes and replace them with a card presentation tray that is easily recyclable.

Nestlé said that the change would save it 200 tonnes of packaging compared to 2007. An additional 17% and 20% will be removed from the weight of the medium and large selection boxes, respectively.

Last Christmas Nestlé reduced the size of its Christmas selection boxes by 40%.

Nestlé's newly opened co-packer IPS First, located next to the Nestlé factory in York, will manufacture the packaging for the selection boxes.

Nestlé Confectionery seasonal marketing manager Andy McQuade said that the challenge was to reduce the packaging "while ensuring the product arrives at the retailer in perfect condition".

"We are really pleased that we've been able to find innovative solutions that have met these objectives and have proved immensely popular with our customers and consumers alike," he added.

The IPS site brought Nestlé's co-packing facilities under one roof and has been estimated to cut 4,000 lorry journeys per year.