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The Life of Plastics Packaging

Green Packaging Conference 21 November 2013 | Jakarta

Geert Van Ballaer | Marketing Manager Borouge Marketing Centre Film & Fibre

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The Lives of Plastics Packaging

Green Packaging Conference 21 November 2013 | Jakarta

Geert Van Ballaer | Marketing Manager Borouge Marketing Centre Film & Fibre

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Content

Borouge

Positioning plastics in packaging

Sustainability in food packaging

Borstar速 solutions

Food for thought 3


Content

Borouge

Positioning plastics in packaging

Sustainability in food packaging

Borstar速 solutions

Food for thought 4


Borouge‌groundbreaking international partnership at the forefront of next generation plastics innovation

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We are a leading provider of polyethylene and polypropylene solutions

infrastructure

automotive 6

advanced packaging


Our mission: “Value Creation through Innovation” ‘Commodity’ path

Feedstock

Olefins

Polyolefins

‘Value Creation’ path

Feedstock

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Olefins

Polyolefins Converters End users

Consumers

Re-use Recycle Recover


Solutions that address major global challenges

Less CO2 emissions

Climate

Safe medical devices

Health 8

Clean water distribution and sanitation

Water

Access to reliable energy

Energy

Food protection

Waste

and safety

Management

Food


Current production capacity Abu Dhabi 

Fully integrated olefins and polyolefins site

Total annual capacity of 2 million tonnes polyolefins

 

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Benchmark for HSE and Operational Excellence in the Middle East

1.14 million t/y of Borstar enhanced PE 800,000 t/y of Borstar enhanced PP

2 Ethane crackers, producing 2.1 million t/y ethylene

The world’s largest olefins conversion unit producing 752,000 t/y propylene


Borouge 3: Supplying growth for the future

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3rd ethane cracker, producing 1.5 million tonnes of ethylene per year (t/y)

Two Borstar enhanced polyethylene units with a capacity of 950,000 t/y

Two Borstar enhanced polypropylene units with a capacity of 900,000 t/y

350,000 t/y LDPE (low density polyethylene) unit with unique technology for Film and W&C

Total annual capacity of Ruwais in 2014 will be 4.5 million t/y – the world’s largest integrated polyolefins plant


Content

Borouge

Positioning plastics in packaging

Sustainability in food packaging

Borstar速 solutions

Food for thought 11


Plastics are used in every part of modern living Around one third of plastics goes into protective packaging

Transport, housewares, crop protection and electronics also rely heavily on plastics

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Plastic packaging is essential to modern living‌ Groceries bought loose and would be cooked on the same day for the whole family...

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...but, we want to shop once a week, have fresh food each day and eat fruit out of season!


Revolution in food / retail packaging

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Waxed paper replaced for dairy products

Boil in the bag

Thermoformed trays

Dairy pots with clickon / peelable lids

Rigid containers for fragile fruit

Vacuum packs Frozen food

Microwaveable pouches

Metalisable packaging


Plastic packaging image Borouge engages in discussions with consumer packaging brand owners and Start the presentation withretailers the “PLASTICS IN RETAILING� video

Together we aim to dispel the myths around plastics and actively work towards a truly sustainable approach to plastics packaging. 15


Myth-buster: Plastics are major contributor to waste…? Plastic packaging means less waste, less energy, fewer resources, less cost and lowest environmental impacts

Plastic packaging does not add to the world’s environmental burden

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Myth-buster: Plastics consume valuable oil‌? Less than 4% of oil and gas ends up in the form of plastic

The average shopper uses more oil driving to the supermarket than is used in all the plastic packaging that protects their goods

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Creating global challenges?

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Addressing the real issues with plastics requires education… Reduce  Overall carbon and water footprint reduction e.g. by material choice, product design and weight reduction

Reuse  Enhance durability and reusability of applications

 Support to reuse alternatives from pallet return to reusable bags

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Recycle  Design solutions allowing recycling and use of recycled material

Recover  Solid Recovered Fuels  Ensure suitability postconsumer plastic waste in energy recovery options


Use of Life Cycle Thinking an essential mindset for sustainability improvement Optimize overall performance by taking the entire life cycle into account

Reduce, Reuse, Recycle, Recover

Consumer

Food

Value National

Producer

Government Chain

Film

Distribution

Converter

& Retailer

optimized with total life cycle in mind

 Polymer products are an essential part of the total product life cycle

 Avoid piecemeal approaches that shift problems from one part of the life cycle to another

Brand Owner

 Close the loop

& Packer

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 System & product design must be

Polymer Producer

Food Producer


How green are plastics? Example: Shrink/Stretch Film

x6

1 kg

Alternative materials

6 kg (metal, paper, cardboard, wood)

142 MJ

x 2.4 58 MJ

Plastic

Plastic

Greenhouse gas emissions (total LC) 8.8 kg CO2-Equiv

x4 2.2 kg CO2-Equiv

Plastic

Alternative materials

Energy consumption (in total life-cycle)

Alternative materials

Comparable mass (equal functional unit)

Use of 1kg plastics saves 84 MJ energy and 6,600g CO2 21

Source: Denkstatt, Germany


How green are plastics ? Example: Woven Fiber bag  Cotton  Highly resource-intensive production

 7,000 – 29,000 liter water per kg  Use of Pesticides  Use of Land

 Polypropylene  43 liter water per kg PP

Plastic Source: Denkstatt, Germany 22

Plastic

Plastic


How green are plastics ? Example: Sacks and Bags Alternative

Borstar PE Conventional LDPE

 Paper bags  Mass x 2.5  Energy x 1.5  Leaching ?

Paper

 Borouge Borstar PE

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 17 % less mass than conventional LDPE

Plastic Source: Denkstatt, Germany 23

Plastic

2 Plastic

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Content

Borouge

Positioning plastics in packaging

Sustainability in food packaging

Borstar速 solutions

Food for thought 24


Impact of plastics packaging on sustainability in the food supply chain 

Packaging represents 4% of all the energy used in the food supply chain

Plastics packaging reduces the overall energy consumed in the supply chain logistics

Food Production 63% Energy Use Mix In Food Chain

Preservation of plastics through downgauging is essential for sustainability

Consumer Use 27%

Retailing 3% Packaging 4%

Transport to retail 3% Source: Table for One, Incpen (2009)

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Extending shelf life...  In the less developed world up to 50% of all food is wasted between harvest and home

 In a ‘packaging-oriented’ society wastage is reduced to around 3%

50% WASTE HARVEST TO HOME

 Modern storage and distribution 3% FOOD CHAIN WASTAGE LONGER ON THE SHELF

reduce spoilage

 Research shows that shrink wrap extends the life of a cucumber on the shelf from around three days to more than ten days

 Extended shelf life means less preservatives plus extended life in the home LONGER IN THE FRIDGE 27


Benefits of plastic packaging? Environmental impact of food distribution

Without plastic packaging, a retailer’s vehicle fleet would make 50% more journeys Source: Plastics Europe 28


Impact of food waste on carbon footprint of fresh meat packaging systems  Example of impact of food waste (meat) on carbon footprint of overall system.

 Seal failures are the leading cause of leaking packages.

 High performance polyolefin-based sealants ensure efficient and safe product distribution.

 Even small increases in seal failures can have a significant effect on environmental impact.

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Carbon Footprint, Relative Value

9 8 7 6 5 4 3 2 1 0 Package Only

Package + Package + Package + 1% waste 2% waste 3% waste

Package Package Product Product Waste Waste (steak) Source: Sealed Air streamlined LCA; not peer-reviewed 29


Packaging Role in Enhancing Sustainability

Processor

Retailer

Consumer

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Need/Opportunity

Packaging Solution

 Spoilage/damage  Production yield losses  Contamination

 Leak-resistant packaging  Barrier technology  Efficient filling systems

 In-store prep losses  Spoilage/damage  Product expiration

 Abuse resistant packaging  Extended shelf life  Vacuum or MAP packs

 Cooked/served too much  Not used in time  Spoilage/damage

 Portion control  Resealable packs  Freshness preservation


Content

Borouge

Positioning plastics in packaging

Sustainability in food packaging

Borstar速 solutions

Food for thought 31


Borstar technology thinner, stronger, tougher!  Unique Borealis’ proprietary technology  Catalyst and process technology enables enhanced polyethylene and polypropylene plastics solutions

 Benefits  Excellent balance of processability and mechanical properties

 Improved properties such as increased stiffness and tensile strength

 Reduced processing costs  Material savings of up to 30 percent  Less energy consumption 32


Benefits of Borstar in preserving resources Cooking oil stand-up pouch

Reference Film (C8 0.926 / C8 0.926 / C8 0.920) 130 µm Borstar Film (C8 0.926 / FB2310 / C8 0.920) 130 µm

The challenge

 Cost reduction pressure of the customer yet maintaining pouch performance The solution

 Borstar PE to replace core layer of an originally 3-layer C8 LLDPE film The benefits

 Higher Dart Impact Strength  Stiffness  Ability to down-gauge by 12% while maintaining 100% pouch performance

 Easy tear  Replacement of more expensive C8 materials Superior stiffness / strength and ability to down-gauge 33

Borstar Film (C8 0.926 / FB2310 / C8 0.920) 115 µm

700 600 500 400 300 200 100 0

656 527

512 448 444 349

1% Secant Modulus (TD) MPa

Dart Impact (g)

50 40 30

39 32 27 22

20

14

11

10 0 Haze %

Tear (MD) (g)


Benefits of Borstar in preserving resources Pallet shrink film using monolayer extrusion The challenge

 Shrinkage MD/TD 60/40%  Good Retention / High Cold Shrink Force  Balance of strength, toughness and stiffness The solution

 Monolayer  Blend: 50% LDPE (MFR 0.3) 50% Borstar The benefits

 Down-gauging >20%  Improved retention/very high cold shrink force  Low hot shrink force, no hole burning  Freedom to tailor the shrinkage properties with  Borstar rich blends 34


Content

Borouge

Positioning plastics in packaging

Sustainability in food packaging

Borstar速 solutions

Food for thought 35


What else can packaging be used for ‌ ?

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The public image of plastic packaging...

Is it right to deprive the world of the use of the most versatile, long lasting, cost effective part of modern living, because we cannot manage waste? 37


The solutions do exist… The solution to litter is not to damn plastic It’s disposal in a responsible way – reuse, recycle, recover!

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Last word‌ A life without plastic?

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Thank you

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Life of Plastic Packaging