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Monomaterial Pouches Refill Durable Aluminum Bottle
In Japan, popular P&G haircare brand Pantene is taking an on-trend route to an improved sustainability profile with a lightweight, beautifully decorated aluminum bottle that’s reusable after its contents have been emptied. The bottle is meant to be refilled with shampoo or conditioner via recyclable pouches, with flexible packaging supplier Zacros providing a unique, monolayer polyethylene solution.
The Pantene stand-up pouch, which Zacros describes as “Japan’s first ever monomaterial refill pouch,” is a PE/PE adhesive lamination where the adhesive provides barrier yet does not interfere with the PE recycle stream. The idea here, of course, is for the consumer to pour the contents into a reusable rigid container and then dispose of the pouch in the PE recycle stream.
The challenge that Zacros had with this monomaterial pouch development was selecting proper materials with only the use of adhesive, ink, and barrier materials of less than 5% by weight, that still provided durability for the liquid. With the company’s unique converting technique, it was able to achieve an oxygen permeability of 4.6cc/m2/24 hours at 30°C, 70% RH condition with two PE layers. By comparison, a single PE film had over 1000cc/m2/24 hours at the same condition. For a hair care product like Pantene, the oxygen barrier property becomes a vital parameter to prevent the permeation of fragrance. In addition, the Water Vapor Transmission Rate (WVTR) of the monomaterial pouch was 1.5g/m2/24 hours at 40°C, 100% RH, while the WVTR of a single PE film was over 2.6g/m2/24 hours. The WVTR is an essential variable in determining the shelf life of products like these. The company says this monomaterial pouch can withstand a drop test for horizontal and vertical orientations, respectively. This P&G Japan monomaterial pouch is only 350-mL. However, Zacros has already extended the development of monomaterial pouch size up to 1.3 L with the durability necessary for liquid products. —Matt Reynolds
The trend of online shopping, which accelerated with the pandemic, is here to stay and will continue to grow, as shoppers become increasingly comfortable with virtual buying formats. That’s according to AMC Global, which advises that as brands update or launch new products, the online shopping environment must be considered in packaging design. Using insights gathered from market research, AMC has compiled the top five packaging considerations for successfully selling online. 1. Design for the digital shelf: Because product packaging may appear much smaller in the digital environment, simplified versioning may be necessary. Product packaging that has been more traditionally designed for in-store and on-the-shelf presence may not be the best approach to meet the online shopper. You must be able to grab attention online with strong, noticeable package images and messages that are clear in purpose, easy to read, and easy to understand.
2. Create clear and concise claims: Online shoppers can’t pick up your package to read long paragraphs describing the benefits of the product or to inspect ingredients effortlessly. Since your package can’t be handled and inspected, the product claims need to be clear and simple, and content lists must be readily apparent. Your package and digital presence must provide all the information necessary for virtual decision making. 3. Get innovative with packaging display online: When designing packaging for virtual display, closely examine all the new promotional avenues available to you in the virtual environment. Online, you have the ability to direct attention by zooming in on certain areas of the package, using video demonstrations, or perhaps showcasing the package in a reallife environment. The possibilities are endless in a virtual world. 4. Adjust physical packaging: It’s not just the visuals and exterior of the packaging that must be considered for e-commerce. Your product is going to be shipped, so you must take that aspect into consideration. A compact design could save on shipping costs, and designing something that is safe and secure for shipping is also important. In addition, using sustainable materials continues to be important in pack designs. Consumers prioritize it and are demanding eco-friendly options. 5. Stay true to the brand: Brand consistency across all selling platforms is vital to brand trust and brand image. Despite the need to adjust many aspects of the package online, you need to also stay true to your brand’s recognized logo, colors, and other globally identifying factors. No matter how many packaging changes and modifications you need to make, don’t lose sight of one key fact: Your brand should be central to all aspects of the design. —Anne Marie Mohan
Bill Nye the Science Guy and Coca-Cola Teach Recycling
As science educator Bill Nye always says, “It’s not magic, it’s science!” And now he’s helping to show the magic, and the science, behind recycling.
The Coca-Cola Company teamed with Nye to unveil an animated, stop-motion short film that illustrates the holistic recycling process. The film breaks down the ins-and-outs of plastic recycling for viewers to demystify the process, with a goal of inspiring action.
“As we know, we need to reuse plastic,” says Nye. “That’s why I’m partnering with The Coca-Cola Company to show the science behind the process of recycling and how we can continue to address the global plastic waste crisis, together.”
Produced for The Coca-Cola Company by Mackinnon & Saunders, the animators and puppeteers behind feature films like Fantastic Mr. Fox, Corpse Bride, and more, the film features an animated (and recycled) version of Nye who explains the end-to-end recycling process. As Nye narrates the process in his dynamic and engaging style, the content takes viewers on the circular journey of a plastic bottle, starting from the time it’s placed in a recycling bin to it coming back on the shelf as a 100% recycled bottle (excluding cap and label).
While roughly 59% of Americans have access to curbside recycling, 27% of plastic bottles are currently recycled in the U.S., according to statistics furnished by the company. The Coca-Cola Company wants to help change that.
One of the company’s goals as part of its World Without Waste sustainable packaging initiative is to collect and recycle a bottle or can for everyone it sells by 2030. The company is also committed to making 100% of its packaging recyclable by 2025 and using at least 50% recycled material in its packaging by 2030. This new film highlights that recycling is critical to “closing the loop,” or using and reusing the materials in plastic bottles again and again.
“We recognize our responsibility to help address the world’s plastic waste crisis and to help create a closed loop economy, but we can’t do it alone,” says Christine Yeager, Director, Sustainability at The Coca-Cola Company North America. “And who better than Bill Nye to help inspire everyone to understand, think, feel, and behave differently about recycling. Still, there’s much more that needs to be done. That’s why we’re also advocating for well-designed collection policy, funding infrastructure, and creating greater economic demand for recycled content. But Step One is collecting and recycling our bottles.”
Creatively, the approach to the film was not just about visualizing this process, but also reflected the use of recycled materials throughout. Beyond the recycled puppet of Nye, packaging materials from Coca-Cola packaging, including plastic bottles, labels, and cardboard were incorporated into every aspect of the short. Trees were made by reusing Sprite labels and conveyor belts designed from recyclable cardboard, creating a film that embodies recycling, design, and function.
Fans can watch the World Without Waste film at CokeURL.com/ClosedLoop, or use the QR code provided in the photo above. —Matt Reynolds
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Colgate-Palmolive and Walmart Shake Up the Dish Soap Category
Watch this video on how to use new Palmolive Shake & Clean
No longer just the realm of entrepreneurial startups, refillable/reusable packaging for household cleaning products has hit the mainstream. In March, Colgate-Palmolive announced the launch of its new Palmolive Shake & Clean Dish Soap product, which features a packaging system made up of a reusable bottle paired with a flexible pouch refill. Together, the bottle and refill are said to result in 75% less plastic waste versus a new 20-oz bottle of Palmolive dish soap. The product is being sold exclusively at Walmart in 2,000 stores nationwide.
Says Joana Baquero, Palmolive marketing director for dish, “Every act of care makes a difference. Sustainability is a core value that we embrace, and we’re excited to further deliver on our commitment to sustainability by teaming up with Walmart on this innovation with a breakthrough new technology.”
The new technology comes in the form of a 4X-concentrated dish soap gel. The concentrate is packaged in a flexible film pouch that holds 5 oz of the gel, in either a Floral Breeze or Fresh Citrus scent. The product formulation also boasts better-for-the planet attributes. According to Palmolive, the “family-friendly formula” is free from parabens and phosphates, and uses 100% biodegradable cleaning ingredients.
The reusable bottle, in the iconic Palmolive dish-soap bottle shape, is made from 100% recycled, clear PET. Two years ago, the company began the transition to 100% rPET, moving all of its ultra dish-soap bottles to recycled material for a reduction in plastic of 5,200 tons per year (see pwgo.to/7545). “We continue this journey with Palmolive Shake & Clean in tandem with Walmart where we can now encourage people to reuse their bottles and lessen their carbon footprint,” says Baquero. Product instructions include three easy steps, advises Palmolive: Fill the empty dish soap bottle with water to a line indicated on the container; add the gel dish soap concentrate; and shake the bottle from side-to-side to activate the formula and produce a 20-oz bottle of dish soap. The Palmolive Shake & Clean Dish Soap is sold as a starter kit, with one bottle and one refill, in a recyclable paperboard carton, for $2.49. Two-pack refill kits, also packaged in a paperboard carton, are sold for $4.78. The products are available in-store and on Walmart.com.
Says Corey Bender, merchandising vice president, household essentials, for Walmart U.S., “Walmart has long-standing commitments in sustainability, including selling products that use less resources and generate less waste. We are thrilled to collaborate with Colgate-Palmolive to bring Palmolive Shake & Clean Dish Soap to our customers, an innovative product that provides very effective cleaning while reducing plastic waste.” —Anne Marie Mohan
Plant-Based Cheeses Improve Formulation and Packaging to Stand Out on Shelves
GOOD PLANeT Foods rebranded its entire line of plant-based cheeses ahead of a large growth projection in 2022, with recent distribution gains in retailers like Giant Martin, Giant Eagle, and Hy-Vee, and increased distribution nationally in Sprouts.
The company changed the communications hierarchy on the package to ensure that it was clear and easy to read. It also paired flavor description with imagery of the application to create appetite appeal. An important visual aspect of the new packaging shows how the product can melt, which can be uncommon for vegan cheeses. GOOD PLANeT selected Belmark’s recyclable flexible pouches for this product.
“With so many new entrants to the plant-based segment, we needed to make sure we approached our new packaging design that it needed to stand out but was also very easy to recognize and shop for,” says Virginia Wong, Director of Brand and Content at GOOD PLANeT Foods. “We updated our font to be bolder and easier to read, reorganized and reprioritized our communication, and we shot brand new food photography that truly showed off the superior melt that our products deliver.”
Along with the rebrand, GOOD PLANeT debuted its newest plant-based snackable cheese wedges, which are packaged in a carton from Amcor that uses 90% post-consumer material and is recyclable. The company says it’s in the process of testing recyclable and compostable packaging for its shreds and slices.
“We have been challenged in finding a better option,” says Wong. “The cheese category has been limited with materials over the year but is committed to finding better options that are more environmentally friendly. All our products have sustainability in mind, and we are pushing to do more toward this goal.” —Natalie Craig
Compact Bra Alternative Gets Luxe Packaging with Detailed Printing
Nuudii System offers grab-and-go “boobwear,” or bra alternative, that gives women an option between wearing a bra and going braless.
Nuudiis are hardware-free and made of 73% nylon and 27% spandex. Since the product is compact and only weighs 1.5 oz., it’s not sold or displayed in retail like typical bras. Instead, Nuudiis are sold packaged and sealed on retail shelves, online, and in special vending machines found in airports, spas, and other retail spaces.
Given the product’s unique shape and retail goals, Annette Azan, Founder and CEO, realized the company needed to come up with a package that lent itself well to the places Nuudii wanted to sell into. The company also wanted the packaging to have a premium feel, enhanced branding and printing capabilities, and a sleek look, which its original package lacked.
“We started with plant-based corn packaging, but it was just really simple,” Azan said. “It wasn’t ideal. The corn packaging is a little crinkly and it can crease. The bags were also non-branded, but we knew we needed to take Nuudii in a different direction. The packaging was a critical part of the branding because Nuudii will never be sold outside of a package or hanging on a hanger in a store. The packaging we have today took a year to develop because we couldn’t find anything that protected the product, that was sealed, and that allowed fine printing. We have printed photography and a size chart on the package. Because Nuudii is small, we needed to have the ability to fine print without losing quality. We were having some huge hiccups with finding fine printing on plant-based packaging.” In March, Nuudii System launched updated, biodegradable, plant-based packaging, helping the company to transition to the desired retail channels. Australiabased Grounded Packaging supplied the pouch, which is made from sugar cane. The package is soft to the touch, something Azan said was important to communicate the experience users will have when they put on a Nuudii.
“It’s beautiful, soft to the touch because this is an intimate product, right? You want all the sensory things that come along with it to take place for consumers,” Azan says. “The color isn’t a stark white, it has milkiness to it, which again, from a sensory point of view, nothing is stark. Everything feels luscious. The whole packaging makes you feel like this is a little bit of a luxury to have.”
The package allows the product to be sealed completely. A hole on top of the package allows it to be hung in retail spaces and in vending machines. The back of the package has detailed graphics showing women the different ways they can wear the product, as well as a sizing chart. The brand was able to enhance its branding and commitment to sustainability with the new package design.
The package is 100% recyclable for every one of the pouches made, the packaging supplier Grounded pledges to remove the equivalent weight and plastic from the oceans.
“On the back of the packaging, we include information about how it’s made from plants and recyclable.” —Natalie Craig
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How Will Inflation Affect Packaging Material Costs in 2022?
Inflationary pressure on packaging materials will continue to rise in 2022 leading to double-digit price increases, with food packaging being a major contributor. That’s according to a new report from Rabobank that covers the 12-month inflation outlook in North America for packaging materials in light of the Russia-Ukraine war.
Notes Rabobank, heading into 2022, U.S. consumer retail demand remains strong. Total retail sales achieved a 10.3% CAGR in the past two years, with goods requiring more packaging than before. In many cases, the demand exceeded the growth in packaging production, leading to a tight food packaging market with high operating rates across various materials, such as beverage cans, corrugated boxes, and PET milk bottles. Meanwhile, cost inflation is increasingly hitting the packaging sector due to increases in energy, transportation, and labor costs. Notes the report, “Along with the ongoing conflict between Russia and Ukraine, these factors will lead to continued price increases of food packaging in the next 12 months.”
In the area of fiber-based packaging, the report reveals that U.S. corrugated containerboard has seen five price increases since the pandemic, which is just one less than in the past decade. Surging e-commerce sales, which jumped 14.3% since 2020, recent cost increases, and a consolidated industry led to ongoing price increases. While fiber is the most important cost component—which in North America is relatively shielded from the impact of the Russia-Ukraine war—other supply chain factors can add up and swing paper prices as well. • Soaring energy costs in Europe have created massive uncertainties for European paper producers. In Q4-21, petroleum-based energy accounted for 3% to 8% of the total cash costs in North America. With a potential 45% increase in crude oil prices, energy costs for paper packaging are expected to increase by 3.4%. • As a result of the expected double-digit increase in transportation costs and rise in fuel costs, production costs are expected to increase by 2.3% to 3.6%. • Cornstarch is a small, yet essential, papermaking chemical in North America, where the market has already experienced tight supply and high demand over the past two years. Since the Russia-Ukraine war, corn prices surged again, with prices now twice as high as two years ago, strongly indicating a continued upward trend in cornstarch pricing.
Due to the short-term capacity constraints and cost increases, Rabobank predicts that corrugated prices may experience double-digit growth in 2022. However, it advises, there is ample supply from conversion and greenfield projects expected to come online starting in 2023.
As for folding carton packaging, Rabobank says it has a more stable demand outlook, but is subject to the same general underlying inflationary factors as corrugated packaging.
In the area of plastic packaging, the report shares that over the last two years, there have been once-in-a-lifetime price increases as a result of weather events, infrastructure breakdown, COVID-19, and labor shortages. But demand for resins remains strong, it says, as the U.S. economy has shown resilience, even in the face of higher inflation and fuel prices.
Prices of major packaging resins, such as PET, were up US$0.26/lb, or 48.6%, in 2021. Recent events in Ukraine continue the upward pressure on packaging resins, with regional PET prices increasing by US$0.20/lb in the first two months of 2022. North America depends heavily on imported material, and there has been no improvement on that front with continued supply issues in domestic PET production.
Says Rabobank, the ongoing war in Ukraine has led to volatility in
global energy markets, pressuring upward movement in packaging resins. Polyethylene suppliers announced an increase of US$0.04/lb in March, with further increases of US$0.04 to US$0.05/lb in April. Polystyrene used in foodservice packaging is experiencing a US$0.05/lb hike due to higher costs for monomers and benzene feedstock. Prices are moving upward all along the resin supply chains.
Despite the price increases, the report notes that some relief is on the way in North America, particularly in PE supply, with several new chemical plants coming online this year. “Most of these plants were originally destined for the export markets,” says the report, “but logistical problems may hinder the 40% export goal and redirect some supply to relieve domestic markets.”
As for aluminum, it has experienced significant price volatility with a price increase of over 40% in the past two years. The U.S. market continues to be dominated by the enormous supply gap that led to 15 billion cans being imported in 2021, or more than 15% of long-term demand in the U.S. On top of the already large supply and demand constraints in the global market, the recent energy price surge has added another layer of inflation to the energy-intensive industry. Says Rabobank, “Not only do we expect higher prices in 2022, but we also expect small beverage producers to face continued risk of aluminum can supply shortage.”
The glass packaging supply chain is energy-intensive and is expected to be heavily impacted by rising energy costs. As the largest importer of glass bottles, U.S. glass bottle supply is more closely linked to the global market, and the impact of the EU energy crisis may be more pronounced. Tight supply, especially for wineries, distilleries, and craft brewers, as well as higher cost, are expected for the next 12 months. —Anne Marie Mohan
“Smaller bubbles, also infused with nitrogen, create an unbelievably smooth, creamy texture made possible by a unique widget placed at the bottom of every can. This is the first time this type of widget technology, often seen in beer and coffee products, is being applied to the cola category and creates the frothy, foamy, smooth texture unique to Nitro Pepsi. It does not look and taste like a traditional cola or soda, and in fact, it’s best consumed differently as well.”
–PepsiCo, as quoted by BeverageDaily.com in an article, “Nitro Pepsi launches in the US: ‘We’re reimagining the cola category!’
“While I have been exiled from Russia since 2000 due to my opposition to Putin, I have remained proud of the Stolichnaya brand. Today, we have made the decision to rebrand entirely as the name no longer represents our organization. More than anything, I wish for ‘Stoli’ to represent peace in Europe and solidarity with Ukraine.”
–Yuri Shefler, founder of Stoli Group, in an article from Beverage Industry magazine, “Stoli Group announces major rebrand”
“Mississippi joins a growing group of states that have passed legislation to encourage the rapid growth of advanced plastics recycling. Republicans and Democrats alike are recognizing the multiple benefits advanced recycling can bring to their states: more plastics recycled, new manufacturing jobs, and reduced dependence on fossil raw materials. We’re delighted to see growing bipartisan action helping to create a circular economy for plastics.”
–Joshua Baca, Vice President of Plastics at the American Chemistry Council (ACC), in a press release from the association, “Mississippi Passes Law to Support Advanced Recycling, Job Growth, and Sustainability”
–Professor Eran Sharon from the Hebrew University Racah Institute of Physics, Faculty of Science, in an article from FoodNavigator.com, “Flat-pack fusilli? ‘Shape-shifting’ pasta developed to reduce packaging”
BY THE NUMBERS
2,000 tons
The amount of plastic a coalition of 20 leading pet food brands together with rePurpose Global is removing from nature each year, which is the equivalent of 111 million plastic bottles or 1 billion plastic bags in weight
#1
Nestlé SA’s ranking in Consumer Goods Technology’s Top 100 Consumer Goods Companies of 2021, with a net revenue of $95.159 billion and a YoY change of 3.2% versus 2020
739 kg
The amount of mixed waste that will be redirected from landfills and turned into UBQ bio-based thermoplastic by UBQ Materials for use by PepsiCo in Latin America to create plastic pallets for two of its DCs
5
The number of bottle designs in total produced by The Coca-Cola company to celebrate Walt Disney World’s 50th anniversary
Mars Champions Women in Packaging
Mars, Inc. Global Vice President of Packaging Sustainability Allison Lin shares her journey in the packaging industry, providing advice to other women seeking a career in the field, and shares Mars’s efforts to enhance inclusiveness in the workforce.
Packaging World:
What are your core responsibilities as Global Vice President of Packaging Sustainability at Mars, Inc.?
Allison Lin:
In my role at Mars, I lead the global cross-segment strategy to improve the sustainability of Mars’s product packaging. We’ve set an ambitious, science-based target to design all of our products for a circular economy. This includes eliminating unnecessary packaging, removing difficult-to-recycle materials such as PVC, and using recycled content wherever possible. We’re also working in partnerships with governments, NGOs, suppliers, packaging developers, and even competitors to drive the systems change necessary to make a circular economy truly possible, including both necessary redesigns as well as infrastructure improvements.
What was your career path to get you to where you are today? Did you have a mentor?
I originally interned on Wall Street at Merrill Lynch and quickly realized that wasn’t the right career path for me. Luckily, Procter & Gamble was recruiting on campus, and I entered the world of packaging—which I knew nothing about at the time except as a consumer. I was offered the opportunity to lead their global recycled and bio-based plastics sourcing strategy, and I fell in love with the field of packaging sustainability. I eventually went to Starbucks, where I got to experience the fiber side of the packaging business as well, and Coca-Cola, where I led the World Without Waste strategy for Closures, Labels, and Films. I recently spent two years on the converter side of the business to get a different perspective leading corporate sustainability at Westfall-Technik before coming back to the brand owner side at Mars. I’ve been extremely fortunate to have many mentors along the way, as well as role models and male allies.
What advice would you give young women looking to get into packaging?
Be the change that you want to see. Sustainability is attracting more diverse talent into the packaging space, and young, diverse talent can bring some unique perspectives to this industry. You will meet people who have been working on packaging for 25-plus years, but you can still bring a unique perspective to improve the industry. Definitely find a mentor and attend conferences to build your network.
How can companies become more inclusive? Are there any special programs at Mars that that focus on diversity and inclusion?
I’ve been lucky that the companies I’ve worked at have been pretty diverse. However, the supply base is definitely not the same. Brand owners take the perspective that our workforce needs to be representative of the consumer base we serve, and packaging suppliers should do the same. Inclusive recruiting is only the first step. Creating an environment where diverse talent can thrive, with representation across all levels and functions of the company, is important to retain talent. Companies should take steps to uncover unconscious bias and promote purposefully inclusive environments.
Mars is working to foster a more inclusive workplace across numerous intersections. We now have more than 50 Associate Resource Groups (ARGs), which we’re leveraging to create spaces and communities for associates of every race, ethnicity, culture, and background to freely and safely engage and express themselves and act as an ally.
We’re also committed to creating opportunities for women to reach their full potential. We’ve already achieved equal pay for our associates and are expanding childcare benefits and flexible hybrid working; challenging stereotypes and bias in our advertising; and investing $1 billion in our diverse supplier program, $500 million of which is women-led. Last year, we also launched a global listening study called #HereToBeHeard to amplify the voices of more than 10,000 women across various intersections—including race, age, sexuality, religion, disability, and more. Mars is leveraging insights from this meaningful dialogue to design and implement new policies and actions to further inclusion. —Anne Marie Mohan
Visit pmmi.org/ppwln to join the Packaging & Processing Women’s Leadership Network to receive information on upcoming events, access professional development resources and learn about ways to get involved.
