Across the planet, we are finding that businesses are investing in creating packaging which can recycle easier, reused more effectively and can promote a more circular economy.
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Dear Readers,
I’d like to formally introduce myself; my name is Emily Gambrill, and I will be filling in the big shoes that Phil has left by becoming the new editor of the SPN magazine. Not the way I anticipated taking the role, but I hope to provide insightful content and make Phil proud.
I hope that you’re all well, now that it’s getting colder and the frost is starting to set on the windscreens in the morning, we can truly say that Autumn has arrived, and even possibly Winter. Even with the cold and bleak weather, SPN strives to providing our readers with the current and exciting news focused on sustainability, specifically in the packaging industry.
In this edition of the magazine, we focus on the advances that are happening in the industry regarding recycling. We also look at how innovative start-ups are changing and evolving the way we can recycle, reuse and repurpose materials in a more sustainable way. We also look into the effects of bio-degradable packaging, particularly surrounding caps and closures.
Finally, I trust you find this edition to be an informative and interesting read. For any further news, please visit our website www.spnews.com. For any content collaborations, please email content@spnews.com and I will make sure to get back to you!
Sincerely,
Emily Gambrill ( Editor )
October 2024
Across the planet, businesses are striving to become more sustainable by developing strategies which will help the consumer recycle and reuse their packaging in more effective ways. We are finding that more businesses are investing in creating packaging which can be recycled easier, can be reused many times and can help promote a circular economy.
Let’s start off with Recycle. There are many benefits to recycling as much as we can. It reduces the need for raw materials and therefore lessens the environmental impact; there is a reduction on landfill waste and products which can be recycled can have a more sustainable lifecycle therefore promoting a circular economy. The list of benefits regarding recycling is endless and, ultimately, it contributes to battling climate change which is essentially the goal we are all aiming for.
UPM Raflatac have announced the launch of its new Packaging Recyclability guide which is designed to help fast moving consumer good (FMCG) stakeholders across the packaging value chain navigate the complexities of packaging design and recyclability. This guide offers practical information on the guidelines, definitions and criteria that affect their decision making and highlights practical information related to packaging design and recyclability. Suvi Rasa, Manager of Sustainability at UPM Raflatac, comments “In today’s market, as legislation and consumer demand both continue to drive a shift toward more recyclable options, companies need to make more informed labelling and packaging decisions”.
On the other hand, as a consumer, we all strive to recycle as much as we can but sometimes this can be difficult. There are too many stipulations regarding what can and can’t be recycled. For example, we can’t recycle cardboard boxes which have grease or food stains on them, and we can’t fully recycle the sandwich packaging that we get from the supermarket without having to tear the whole thing apart. Not only the consumer, but the companies as well, are facing issues. Speaking at the Circular Economy Stage at Packaging Innovations 2024, Julien Tremblin, General Manager at TerraCycle Europe, explains “If we go to a company and say ‘We can recycle your packaging, it’s going to cost you money to do so, but you should do it for the good of your heart,’ we’re going to hit a brick wall,”. Julien goes on to say, “We need to find some return on investment one way or another. That can take many forms, whether it’s the value of the recycled material or the value of the PR and marketing that it creates.
companies are facing, now more than ever, with the current global situation. This is not based on purchasing better recyclable packaging, which is going to cost more, but by changing the behaviours of the consumer by providing incentives. Julien explains “Retailers have an oversized role to play. That is where people purchase products, so it’s where people should return them for recycling. We’re working with Wal-Mart (the US-based supermarket chain) to collect 12 different waste streams at the car parks of WalMart stores. This system involves giving the end user a coupon that they can redeem for their next purchase of the product they have just returned for recycling, so there is an economic incentive for the consumer and retailer.”
Crucially, this approach also solves the problem of separating out different materials – the consumer does this when they drop their old toothpaste tubes, razors, or blister packs into the relevant receptacle. “It’s extremely important to sort waste at the source to ensure we apply the right recycling solution,” he explains. “Then we aggregate and send for recycling at our partner sites.”
As we all know, this concept will not be implemented overnight, but it is certainly a step in the right direction.
On the flip side, we look at Reuse. This is the ideal solution as there aren’t any processes which are not cost effective, affect the climate or can make the process of recycling more difficult due to contamination issues. There are plenty of ways that we, as a consumer, can reuse products. We start off with the bags we purchase from the supermarket to carry our goods home in. Initially, we were in uproar about the cost of these bags, but as we reuse them more often, we are finding that the initial outlay is now cost effective as we don’t pollute the planet with plastic bags which historically were only used once before being put in household waste.
Furthermore, Ocado Retail has become the first major supermarket to pilot a new reusable packaging scheme, specially designed for online, to reduce the use of single-use packaging from customers’ weekly shops. The trial, staged across two phases, will use a reusable vessel, developed specifically to deliver food cupboard staples and laundry products at scale, with no extra cost to the customer. It has been said that if every household in the UK reused just one item, it would eliminate approximately 1.4 billion items of single-use packaging per year. Research among more than 2,000 consumers undertaken by Ocado Retail and Savanta revealed that there is growing public demand to reduce the use of single-use plastic from grocery shops. Simon Hinks, Product Director at Ocado Retail says “We’re proud to be the first major supermarket to pilot an online reusable packaging scheme. Most people understand the concept and know it works in a physical store but this trial brings the solution straight to customers’ doors. Our customers are already used to giving their bags back to our drivers for recycling - so this is a really sensible next step for us to help our customers reduce single-use plastic on products they buy frequently.”
Also, goplasticpallets.com are launching a new rental service which has Reuse at the core. The rental service is designed to offer greater flexibility and cost-effective access to premium supply chain solutions, enabling customers to focus their financial resources on core business operation, while simultaneously greening their supply chains. Goplasticpallets.com go on to say that the customer can choose from a select range of plastic pallets, including long-lasting heavy-duty pallets and sleeve packs, available on a long-term basis. Now, I know that a moment ago we were explaining that plastic requires a lot of energy to recycle, and it uses raw materials to make which, as we are becoming increasingly aware, there is not an never ending amount. Reusing it in this way is one of the best ways of using plastic packaging in a fast growing sustainable world. Jim Hardisty,
Managing Director of goplasticpallets.com said “We are excited to launch our new rental service, which provides our customers with a wider variety of options tailored to their unique budgets and operational needs. Our extensive experience in logistics and supply chain management allows us to develop new solutions that not only meet but exceed the expectations for efficiency and costeffectiveness.
“Our growing portfolio of services reflects our ongoing commitment to supporting our customers by providing additional value at every opportunity. We will continue to look for ways to innovate and support the industry, reinforcing our role as a trusted partner in sustainable supply chain solutions.”
However, like with Recycling, we look at the disadvantages of reusing products. As briefly explained above, the initial cost and investment is higher than using single-use packaging. For new businesses, this can mean that initially it is not feasible to follow this path, but it does provide an avenue to follow once business become more established and are therefore able to modify their packaging streams. Also, as reusing packaging can often require systems to ensure the products are clean, in working order and have them returned to the manufacturer, this introduces complexity in logistics and can increase operational costs, which are then ultimately passed to the consumer. Following on from the previous point, this can be solved by ensuring that businesses invest in infrastructure which is able to withstand demand. We always come back to it, but without changing the behaviour of the consumer to be more sustainable, we are not implementing solutions which help us become eco-friendly. This can be a barrier when it comes to reusing packaging. There are times when the consumer is not able, or willing (but hopefully the latter), to return packaging for reuse. But this can be solved by educating people on the benefits of reusing packaging and how it can help battle climate change.
To conclude, both recycling and reusing packaging are two essential strategies for promoting sustainability. As we have learnt, both ways help reduce landfill waste, lower carbon emissions and help promote a circular economy. However, this doesn’t come without challenges such as the need for investment in infrastructure, changing consumer behaviour and simplifying processes which, as a consumer, we find laborious.
When it comes to waste hierarchy, reuse will always supersede recycling, coming third only to prevention and reduction (ref1). But the relationship between reuse and recycling is far more complex than where they stand in the waste framework directive’s ranking. Industry statistics show that while it sits higher in the sustainability pecking order, reuse still has some way to go to gain the same consumer buy-in as recycling.
That’s not to say that the job is done when it comes to recycling – far from it –but there is clearly greater acceptance of it than reuse.
According to latest Government figures, 64.8% of UK packaging waste was recycled in 2023. In contrast, according to the Circle Economy (ref2), of the 15.3 tonnes of material consumed per capita in the UK, only 7.5% of this material is being used again.
As we strive towards achieving net zero and creating a more circular economy, reuse will play an integral role in how we effectively manage waste. However, as with recycling, there are a number of barriers that stand in the way, with levels of consumption and consumer behaviour high on the agenda.
Environmental charity, Hubbub, estimates that 11 billion pieces of single-use plastic are needed each year to fulfil the UK’s appetite for lunch-on-the-go. It will take some considerable effort to create a reusable market to satisfy that demand, drive genuine behavioural change – not to mention a better recycling system to clear up the remainder.
Convenience, cost, reassurances around hygiene, incentives and logistics, are just a few issues that still need to be overcome, in order to refine the reuse system. However, what is clear is that across retail, hospitality and leisure, efforts are being made to stimulate
engagement in recycling and reuse, whether it’s supermarket take back schemes for soft plastics, or returnable cup trials run by some of the world’s biggest coffee chains.
Collaboration is key. So too is the role of legislation, policy and investment by the Government to create a more robust infrastructure – both for recycling and reuse. While the spotlight has recently been placed on the recycling efforts of big-name brands, the real questions should be asked of ministers.
For example, from 2022 to 2024, HMRC collected over £553 million in Plastic Packaging Tax (PPT) revenues. However, there’s very little information about how this new revenue is being used. Is it being reinvested in supporting the PPT’s aim to stimulate increased demand for recycled plastic?
Infrastructure is key for reuse and recycling to be a success. Unfortunately, in this country, there is a complete lack of closedloop recycling facilities to sort and process the same types of plastic packaging to avoid downcycling and converting to energy and fuel. Perhaps PPT revenues could be utilised to help develop closed-loop recycling facilities in the UK? Or, could revenues be invested in public education and awareness that encourages recycling behaviours and boosts recycling rates?
Greater emphasis must be placed on educating consumers on the benefits of both reuse and recycling. Engagement from them, as well as from invested retail and hospitality stakeholders, will go a long way in helping to drive the sustainability agenda forward.
References:
1. https://www.circle-economy.com/news/uk-population-consumes15-3-tonnes-of-materials-per-person-per-year-20-more-than-theglobal-average
2. https://www.circle-economy.com/news/uk-population-consumes15-3-tonnes-of-materials-per-person-per-year-20-more-than-theglobal-average
Sales of pre-used cardboard boxes have trebled in the past 12 months for Priory Direct, which supplies sustainable packaging to more than 21,000 businesses. The firm has gained almost 200 new buyers for its range of used boxes, whilst many existing customers significantly upped their spend. Most of these customers are retailers, in particular of clothing, furniture, toys and online gifts.
Cardboard is a durable, versatile and usually 100 per cent recyclable packaging material, particularly if made using Forest Stewardship Council (FSC)-approved materials and sealed with paper tape rather than plastic tape. Compared to other packaging materials, the manufacturing process is less carbon intensive and where the wider supply chain has focused on reducing emissions in manufacturing and distribution, cardboard can be a climate neutral packaging choice.
Priory Direct’s Managing Director, Josh Pitman, believes the trebling in pre-used box sales is evidence that the packaging industry is becoming more circular and that retailers are truly embracing sustainability.
Pitman, whose Kent-based firm is working to lower the environmental impact of ecommerce, says:
“In a world where a growing number of retailers, including big name brands, are embracing the circular economy by refurbishing, repairing or re-selling pre-used stock, packaging has a significant part to play. Used boxes are a way for retailers to further reduce the impact of their operation and also save on costs. I think the three-fold increase we have seen in used box sales also reflects the changing attitude and expectation of consumers.”
Priory Direct has also begun shipping more than 90 per cent of its own stock in used cardboard boxes, saving the business approximately £90,000 per year.
As well as cardboard’s suitability for reuse, at end of life, cardboard recycling rates in the UK have been consistently high in recent years, making it one of the most recycled packaging materials. According to Defra statistics, 73% of paper and cardboard packaging was recycled in 2023, compared with 53% of plastic packaging. Cardboard is also biodegradable, with corrugated cardboard generally degrading completely within a year thanks to its cellulose composition.
Pitman concludes:
“The packaging industry needs to move towards greater circularity. Transparency and ensuring a sustainable end of life is part of the manufacturing process for all our packaging products, but if we can first get as much use out of our packaging as possible, their sustainability credentials increase even more.”
“I think the three-fold increase we have seen in used box sales also reflects the changing attitude and expectation of consumers”
The packaging industry is undergoing a transformative shift, driven by growing demands for sustainable solutions that align with new regulations and consumer preferences. At the forefront of this change is Easysnap Technology dedicated to developing innovative single-dose
One of its leading products, Papersnap®, embodies the company’s commitment to sustainability, usability, and universal design. Papersnap® reflects the principles of the proposed Packaging and Packaging Waste Regulation (PPWR) by the European Union, aiming to reduce environmental impact and promote recycling within the packaging industry.
Founded with the mission of revolutionizing single-dose packaging, Easysnap Technology Srl – part of the global flexible packaging company Gualapack - has developed patented solutions that combine functionality and sustainability. The company’s single dose Easysnap® packaging introduced a new way to dispense liquid and semi-liquid products using a one-hand opening technology, making packaging accessible and convenient for all users. Building on this patented design, Easysnap Technology created Papersnap®, a paper-based version of the original concept, offering even greater sustainability without compromising the user experience.
At the heart of both Easysnap® and Papersnap® is the patented onehand opening technology. With a simple folding motion, the pack opens and dispenses its contents in a controlled manner, making it easy for anyone to use, including children, the elderly, and those with
disabilities. This universal accessibility is a core principle of Easysnap Technology, making their products inclusive and functional for all users. This is particularly advantageous for on-the-go use, allowing consumers to enjoy products wherever they are without the risk of mess.
Papersnap® represents the next generation of sustainable packaging. Made up to 85% of paper, it maintains the ease-of-use and practicality of the original Easysnap® concept, while being fully recyclable with standard paper waste streams. This environmentally friendly approach aligns with the objectives of the upcoming PPWR, which aims to make all packaging reusable or recyclable by 2030.
Unlike many single-use packaging options that often incorporate various components, Papersnap® is a one-piece solution with no detachable parts. This makes it simpler to recycle, contributing to a cleaner environment.
One of the standout features of Papersnap® is its focus on sustainability throughout its lifecycle:
• Recyclable Materials: Composed primarily of paper, Papersnap® is recyclable with paper waste, simplifying the disposal process and promoting responsible recycling practices
• Reducing Packaging Waste: With no tear-off parts, Papersnap® generates minimal waste, aligning with environmental goals to reduce waste pollution.
• Food Waste Prevention: The single-dose format ensures only the required amount of product is dispensed, reducing food waste and providing a practical solution for portion control.
Papersnap® is a versatile packaging solution that meets the
needs of diverse market segments, including food, cosmetics, and pharmaceuticals.
Thanks to its flexible filling range, from 0.1 ml to 30 ml, and its user-friendly design, it offers a wide variety of options for different products. Consumers can drink, pour, dress, or spread the product directly from the pack, providing an optimal experience for various uses.
Easysnap Technology offers flexible business solutions to help brands integrate its innovative packaging. As a producer of automatic packaging machinery, the company enabling brands to produce Easysnap® and Papersnap® packaging in their own facilities. Alternatively, Easysnap Co-packing service offers a full contract packaging solution, where the company manages every aspect of production, from filling to final packaging. Both options give brands efficient, user-friendly packaging that enhances product appeal while meeting consumer demands for convenience and sustainability.
For further information contact: Alessio
Bonizzato, Marketing Communications Specialist Email:
alessio.bonizzato@easysnap.com
by Dominy Jones
Sustainable beverage packaging is becoming increasingly important as both companies and consumers focus on reducing environmental impacts. Various materials like metal, glass, plastic, and paper are being reimagined to meet sustainability goals, while deposit return schemes (DRS) are gaining popularity as a way to encourage recycling.
Aluminium cans have long been a popular choice for beverage packaging due to their high recyclability. Aluminium is infinitely recyclable, meaning it can be reused without losing quality. This makes it a sustainable option for beverage containers, as recycled cans use up to 95% less energy than producing new ones. The lightweight nature of aluminium also contributes to reduced carbon emissions during transport, making it a strong contender in the sustainability race.
Eco-functional drinks brand Water Almighty have announced the launch of two innovative aluminium-bottled waters. Melvin Jay, founder of Water Almighty, commented: “Our aluminium bottles offer a real solution to the plastic crisis, being endlessly recyclable and reusable. We’re proving that consumers and retailers don’t have to choose between health, convenience, and environmental responsibility—they can have it all in one mighty package.”
Glass bottles, while heavier than other materials, offer a longterm sustainability advantage due to their ability to be reused and
recycled. Many beverage companies are moving towards using more recycled glass, which lowers energy consumption and reduces the need for raw materials like sand. However, the weight of glass bottles can increase carbon emissions during transportation, which is one of the key challenges the industry is trying to overcome.
Ardagh Glass Packaging-Europe have launched a new lightweight range of standard wine bottles produced in Germany for the European market. Stuart Santon, Chief Commercial Officer, AGP-Europe said: “These new lightweight wine bottles in a range of colours and finishes offer our customers versatility and choice, while reducing the carbon footprint of their glass packaging”.
Plastic, particularly PET (polyethylene terephthalate), is widely used in the beverage industry because it is lightweight, durable, and inexpensive. While plastic has a negative reputation due to pollution, advances in recycling technology are helping to reduce its environmental impact. Companies are developing more recyclable plastic packaging and increasing the use of recycled content in new bottles. Some are even exploring biodegradable or compostable plastics. However, improving recycling rates and reducing single-use plastics remain critical for long-term sustainability.
Zotefoams is currently in the latter stages of developing ReZorce for beverage carton applications and is preparing for trials with a north European supermarket chain. Currently available aseptic beverage cartons are produced from composite layers of wood fibre, aluminium and polymer bonded together. Unlike ReZorce, these composite materials cannot be recycled through mainstream processes. ReZorce on the other hand has a mono-material design which leads to excellent performance in standard Material Recovery Facilities.
Neil Court-Johnston, President of Zotefoams’ MuCell Extrusion LLC business unit, said “Where reusable packaging isn’t an option, brand owners need alternatives that are easily recyclable through existing infrastructure and can be used in the same application time and again, with a reduced environmental impact. ReZorce is just such a material, and adopters will benefit from lower EPR fees, while knowing that they are doing the right thing for the environment.”
Paper-based alternatives, such as cartons and newly developed paper bottles, are gaining attention as eco-friendly options. These materials, often used for milk, juice, and water, are designed to be easily recyclable and compostable. Paper packaging typically uses less energy in production compared to glass and metal. However, most paper cartons are lined with plastic or aluminium, to prevent leaks, which can complicate recycling efforts.
KinsBrae Packaging manufactures KB Bottles - the world’s first commercially available paper bottle designed for non-carbonated beverages and oils. Made from 100% recycled paperboard, they are five times lighter than a normal glass bottle, weighing just 83g. KB Bottles have a carbon footprint up to six times lower than a glass bottle; they use 77% less plastic than a plastic bottle, and their water footprint is four times lower than a typical glass bottle.
Deposit return schemes (DRS) are increasingly being adopted in countries around the world to incentivize recycling. Consumers pay a small deposit when purchasing a beverage and can reclaim it when they return the container. These schemes have proven effective in increasing recycling rates for plastic, metal, and glass containers. Countries like Germany, Norway, and Lithuania have reported recycling rates of over 90% with DRS in place. As more countries implement similar systems, DRS is expected to play a significant role in reducing packaging waste.
Labour environment minister, Mary Creagh, indicated she would stick with Conservative proposals to exclude glass from the Deposit Return Schemes in England and Northern Ireland. It was widely hoped that Labour ministers would follow the approach taken across much of Europe, by including glass bottles within England’s scheme, paving the way for a consistent approach across the United Kingdom.
Owen Derbyshire, Chief Executive of Keep Wales Tidy, said: “Creating an ambitious and glass-inclusive deposit return scheme is vital for protecting both people and the planet. The Welsh Government’s proposals, which include glass, offer a ready to-go blueprint for the rest of the UK, enabling us to meet the clear calls from the public to ensure we have maximum possible protections for the environment. Ministers should carefully consider how they will ensure adequate levels of protection are achieved in the absence of a wide-ranging deposit return scheme like we see across much of Europe.”
Sustainable beverage packaging is advancing rapidly across different materials and systems. Whether through improved recyclability, reduced material usage, or innovative return schemes, the industry is moving toward a future where environmental impact is significantly reduced.
by
As a connected packaging specialist, I recently attended the Innovations in Non-Alcoholic Beverages conference in London. The standout themes included reshaping beverage packaging to ensure it is sustainable, personalised and connected. Sustainability leads the way
Sustainability has become a core consumer expectation. Coca-Cola’s adoption of KeelClip™ in Europe, a minimalist paperboard packaging for multipacks, is projected to save 2,000 tonnes of plastic and 3,000 tonnes of CO2 annually.
Diageo’s trial of a 90% paper-based bottle for Johnnie Walker Black Label scotch whisky is a groundbreaking development. This prototype could reduce carbon emissions by 47% compared to standard glass bottles and is 60% lighter. The bottle features a thin plastic liner that doesn’t impact recyclability, allowing for easy separation during recycling.
Digital printing technologies are revolutionising beverage packaging design, enabling limited editions and individually customised bottles. Brands are using variable printing to create unique patterns or codes on each bottle, turning them into collectibles. Others are implementing AI-driven personalisation, where designs change based on consumer preferences or real-time data. In some cases, even recipes are customised with highly personalised ingredients using data points specific to the consumer.
At Appetite Creative, we’ve found that personalised connected experiences significantly increase engagement times. When consumers feel that a brand is speaking directly to them, they’re more likely to interact with the packaging and develop brand loyalty.
Connected packaging is transforming beverage containers into interactive touchpoints. A great example is our work with Elopak’s new aluminium-free carton, which Don Simon has started using for its beverages. We were able to raise awareness of the new aluminium free carton, personalise the experience by product type, test customer knowledge and address the gaps and drive sales. All while identifying ambassadors for the brand. We saw an average dwell time of two minutes and 46 seconds, 14% scan rate and 60% registration. The convergence of sustainability, personalisation and connectivity is driving the future of beverage packaging. The rise in use of QR codes, IoT and 5G will enable real-time data exchange between packaging, consumers and brands. Leading to innovations like dynamic pricing or automatic reordering systems. For beverage brands, embracing connected packaging is about creating meaningful, personalised experiences that resonate with consumers while promoting sustainability. The future of beverage packaging is connected, sustainable and personal, and I’m thrilled to be at the forefront of shaping it.
by Adriana Dale, Marketing Director Global Beverage and Machinery, Graphic Packaging International
In an era where the call for environmental responsibility echoes louder than ever, the paperboard packaging industry is wellplaced to respond. As consumers become increasingly aware of the environmental impact of their choices, and as climate change climbs higher on the global agenda, the need for circular beverage packaging solutions - such as those constructed from paperboard - has never been more pressing. Regulatory shifts and evolving consumer demands are reshaping the landscape, compelling beverage companies to re-evaluate their approach to packaging design and production.
The design of secondary paperboard packaging solutions for beverage plays a pivotal role in minimising its environmental impact and maximising its compatibility with a circular economy. Design for Environment (DfE) is an approach to reducing the overall human health and environmental impacts of packaging across its entire life cycle. At Graphic Packaging, by integrating DfE into the design process, we design and deliver secondary packaging solutions that are more convenient, more functional, and more circular.
While optimising circularity must be a primary aim when developing new packaging concepts, the ability of that packaging to perform throughout the supply chain and onto the retail shelf is equally important.
From a beverage producer’s point of view, product damage elimination, material reduction, energy reduction, operational
efficiency, and the ability of the pack to effectively promote the brand are all important. Great design can also deliver opportunities for beverage producers to reduce or even eliminate tertiary packaging. As an example, we recently conducted a study looking at optimising pallet configurations for can multipacks in trays and shrink film. Switching to a standard fully enclosed carton enabled direct palletisation, removing the need for shrink film and stretch wrap. This move yielded significant energy and CO2 savings (75 percent and 72 percent respectively) along with a 10 percent increase in the number of cans per pallet.
Retailers have an influential voice in any conversation about packaging design. They regularly review their own guidelines to ensure the packaging on their shelves aligns not only with their own packaging goals but also with the expectations of the consumer. This can include packaging weight reduction, plastic reduction, the addition of recycled content, and incorporating solutions that are easy to merchandise and easy for consumers to handle and recycle.
When creating secondary paperboard packaging solutions with their packaging partner, producers must achieve these goals without compromising on the consumer experience. Appeal on-shelf, safety and comfort when carrying, ease of dispensing, and the ability to recycle in household waste streams are important factors. It’s also critical that the pack performs well through the supply chain and arrives on-shelf in excellent condition, as 58 percent of consumers state that packaging damage would deter them from purchasing a product.
Taking a holistic approach to secondary paperboard packaging design that’s supported by DfE principles can deliver better results, meeting the needs of beverage producers, their customers, and their consumers more fully.
As global brands seek more eco-friendly solutions in response to mounting consumer and regulatory pressure, advancements in packaging materials are driving sustainability initiatives forward. Klöckner Pentaplast (kp), a leader in sustainable packaging, offers SmartCycle® Pro, a pioneering material for shrink-sleeve labels used in the beverage and food industry. This innovation not only promotes recyclability but also offers a solution that meets evolving market demands for circularity.
Shrink sleeve labels play a crucial role in product preservation and branding, but it also faces increasing scrutiny due to environmental concerns. Shrink sleeves, often used to provide 360-degree design coverage and visual appeal, have traditionally posed challenges for recycling. The full-body labels are typically made of materials that are incompatible with bottle recycling systems causing recyclers to add a de-labeling step to their process.
Brands have been seeking a solution that allows them to maintain impactful designs while also improving the recyclability of their packaging. SmartCycle® Pro allows brands to achieve both. SmartCycle® Pro is kp’s solution to the sustainability challenges facing the industry. What makes it stand out is that it’s not only fully recyclable along with the PET bottles it’s applied to, but it also contains 30% post-consumer recycled content, supporting the circular economy.
With this breakthrough, kp enables brands to close the recycling loop, reducing the volume of packaging waste sent to landfills. This contributes significantly to reducing the carbon footprint of packaging, aligning with the global push for carbon reduction and sustainability.
In addition to its recyclability, SmartCycle® Pro offers brands even more advantages. It allows companies to showcase their commitment to sustainability while still delivering the vibrant, attention-grabbing designs needed to stand out in a competitive market
From a performance standpoint, the shrink-sleeve labels are engineered to meet the rigorous demands of packaging, offering durability, clarity, and high shrinkability without compromising on aesthetics.
For consumers, this innovation provides the reassurance that the products they’re purchasing are designed with recycling in mind, supporting their desire for environmentally responsible choices. It reinforces the idea that their purchasing decisions contribute to a more sustainable future, aligning with their values of reducing environmental impact.
SmartCycle® Pro is a step toward realizing true circularity in packaging. By incorporating recycled content and facilitating full-package recyclability, kp is helping brands shift towards more sustainable models of production and consumption. This move is in line with global legislative efforts that are mandating stricter recycling practices and higher levels of recycled content in packaging.
SmartCycle® Pro reflects kp’s broader commitment to sustainability. With an ongoing focus on reducing plastic waste and supporting the recycling infrastructure, kp is leading the charge in developing solutions that not only meet today’s market needs but also anticipate future environmental challenges.
Through innovations like SmartCycle® Pro, kp is empowering brands to take meaningful steps towards reducing their environmental impact while continuing to deliver high-performance, visually striking packaging.
The Pure-Pak® carton is a sustainable, convenient and consumer-preferred alternative to plastic bottles. Choosing fiber-based packaging for conserving liquids is better both for the consumer and the environment.
In an impressive confirmation of the company’s commitment to sustainability, KHS has again been awarded the coveted gold status by rating agency EcoVadis. The Dortmund systems supplier has further improved over last year’s assessment – now earning 73 points out of 100 in the completely revised evaluation method.
In taking part in the EcoVadis audit, KHS has had its commitment to sustainability, especially within its global value chains, verified since 2012. Increasingly strict requirements – necessitated in Europe in particular by the regulations of the European Green Deal – have caused the rating agency to make fundamental changes to its principle of assessment. This has resulted in renewed intensification of all of the rating criteria. The benchmarks in the assessed categories of environment, labor law and human rights, ethics and sustainable procurement have been significantly raised. This has led to greater competition between the participating companies and made the procedure even more demanding with regard to the results achieved to date and their associated rankings. Moreover, annual updates of EcoVadis’ evaluation criteria mean that requirements governing proof of performance during an audit have also been tightened. In short, companies thus need to constantly strive to improve their commitment to sustainability.
“Strong signal for the KHS Group”
In this context, KHS GmbH CEO Kai Acker considers the company’s renewed gold status to be a particularly great success. “This is a strong signal for the KHS Group and our customers and provides further confirmation of our commitment to the protection of the environment, ethical business practices and social responsibility.”
Besides the names of the medal winners, the assessment period and percentile are now also published. Of all companies evaluated – regardless of their branch of industry –KHS is therefore among the top 5% with its commitment to sustainability. The engineering company is thus consistently pursuing its aim to reach net zero within the Group by 2050. “With our second gold award, we’re creating a reliable and credible basis for assessment of our commitment to sustainability for our customers especially,” explains Acker.
EcoVadis is one of the world’s key platforms for the assessment of corporate sustainability achievements. It aims to provide interested parties from various sectors and markets with a reliable summary of the quality of management systems and the associated risk management setup of companies in the supply chain. The EcoVadis database currently contains more than 130,000 rated companies from over 180 countries and 220 different sectors.
For more information, please visit: www.competence.khs.com/en/ company-news/second-gold-for-khs
The evolution of plastic packaging manufacturer RETAL has seen it grow beyond a converter and producer to a complete packaging solutions partner to household name brand owners worldwide.
Established in the early nineties and headquartered in Limassol, Cyprus, RETAL, part of RETAL INDUSTRIES LIMITED, now operates 10 production facilities in eight countries. Throughout its 30-year history, RETAL has worked to create a strong balance of reliability and innovation, creating plastic packaging solutions that allow brands to meet all regulations in their active markets.
Maria Jarrar, Senior Marketing Manager EU & US, explains how the company’s long-term dedication to making it easy to choose RETAL influences its investments and capabilities. She says, “RETAL always makes sure our customers are on the safe side. We take great care to stay ahead of changing legislation and regulations across our markets so that our customers can be sure that choosing RETAL means their products are packaged right.” This ‘safe side’ is illustrated by a series
of practical actions from RETAL, including its extensive portfolio, rPET usage, investment in R&D, provable sustainability actions, and its famous after sales service.
Jarrar continues, “Our capabilities show that our product portfolio is always in line with what our global and local customers require. We walk that line of innovation and commodity carefully so that everyone can find what they need with us. We have a big portfolio of preforms with various neck finishes to suit all our active markets, with both tethered and non-tethered closures. Our ever-growing tethered portfolio includes 26/22 GME30.40 and we’re planning to increase this with further investment in the near future.”
To ensure the quality of the portfolio, RETAL also invests in quality across its locations and its dedicated R&D laboratory in Lithuania, where the quality assurance team is based. Jarrar explains, “Quality underpins everything we do; we have built our reputation on delivery reliable quality, so it is imperative that we continue to invest in new machines, in state-of-the-art testing equipment and in our impressive facilities. The influence of our R&D capabilities is felt throughout RETAL; from the development of lightweight preforms to innovative tethered closures that meet evolving regulations, our experienced team of designers are constantly finding new ways to deliver excellence.”
There is also considerable experience in using rPET at RETAL, with the company integrating recycled material for over 10 years already. Supported by preferential supply from sister company NEO Group, a Lithuania-based polyols producer that is one of the largest in Europe, RETAL is able to offer a reliable supply of NEOPET Cycle to its customers. Virgin PET resin with 25% of recycled content already integrated, NEOPET Cycle helps brands to meet sustainability targets without requiring additional investment or equipment modification.
RETAL sister companies also include Orzuplast, T.O.O PET and Caucasian PET, PET packaging producers in Uzbekistan, Kazakhstan and Georgia respectively. Jarrar explains, “With our strong network, we can guarantee strong supply of quality assured plastic packaging for brands across these local markets, both for local companies and global brands that are active in these exciting, growing regions. We have already proved that we work proactively with customers to implement tethered closures in line with regulations and we have a strong experience of working with rPET.”
Sustainability is certainly as important to RETAL as it is to its established customer base that includes many of the world’s leading brands in both global and local markets. The company is vocal in reaching ambitious targets across all its factories, with Chief Sustainability Officer Emmanuel Duffaut a driving force in educating and actioning high standards including validating SBTi, gaining an ACDP score and using up to 100% renewable energy where possible.
All RETAL plants benefit from the experience and capabilities of the RETAL Service team, a group of 11 engineers that are on call 24/7, ready to solve any issues on site or remotely, wherever a customer may be. Lead by Head of RETAL Service Vladislav Medvedovskiy, the team is well-known as a fast response, solutions-focused service that freely shares support with customers, helping to give peace of mind. Jarrar concludes, “This complete service is representative of the evolution of RETAL over the years. We’re proud to deliver a complete packaging solution to our customers, from advising on tethered closure implementation to quickly bringing a spare part to keep downtime to an absolute minimum. RETAL always finds an answer.”
Gradually, it is becoming the norm to purchase our clothes, tv’s, games and even our grocery shopping online. It is more convenient, it lowers carbon emissions and contributes to our global effort to becoming more sustainable. Even though we are hearing more about how ecommerce businesses are becoming more sustainable, they still have a way to go. Emily Gambrill reports.
Ecommerce is becoming more popular as technology evolves, and certainly since the Covid outbreak. Let’s start off with the positives of ecommerce; ecommerce businesses are adopting minimalistic, recyclable or biodegradable packaging which in turn reduces the overall environmental impact of shipping. We have news from Hugo Beck, a leading innovator in horizontal film and paper packaging machines, on its introduction of significant upgrades to its product line.
“Delivering sustainable packaging solutions with increased speed and efficiency continues to drive innovation at Hugo Beck,” said Timo Kollmann, Managing Director at Hugo Beck. “Our goal is to futureproof our customers’ packaging processes through the integration of fully automated packaging machines like the paper e-com rapid. This helps reduce downtime, improve product packaging quality, and enhance efficiency and sustainability.”
Also, we find ourselves in a world where second hand goods are becoming the latest trend and fashion. Businesses such as eBay, Vinted and ThredUp, help to contribute to the circular economy by extending the life cycle of products and reducing the need for new production. To further illustrate my point, eBay has released statistics surrounding its achievement in sustainability. Renée Morin, Chief Sustainability Officer at eBay, explains, “Sellers and buyers worldwide embrace eBay’s recommerce for its economic benefits and positive impact on the planet, with pre-owned and refurbished products now making up 40% of our GMV (Gross Merchandise Value). In 2023, eBay created $4.9 billion in positive economic impact, while avoiding 1.6 million metric tons of carbon emissions and 69,000 metric tons of waste. Through recommerce, we’re extending the life of products, diverting them from landfills, and empowering customers to make sustainable choices. We’re also well on our way to achieving 100% renewable energy for our data centers and offices, and we’re investing in clean energy initiatives around the globe.” (Reference: www.ebayinc.com/impact/sustainable-commerce/)
This is great for the giant businesses such as eBay, but what about the small, independent sellers? Ben Ginesi, European Sales Manager at Domino explores this further.
“For the majority of these small, home-based ecommerce sellers, partnering with a packaging provider using traditional printing methods is unlikely to be an option. Minimum order volumes are too high, and sellers often need more storage space for large numbers of boxes.
However, with digital printing, small ecommerce businesses and their customers need not miss out on the unboxing opportunity. With a growing number of service providers dedicated to digital printing, businesses of all sizes can now commission short runs of eyecatching, even personalised, packaging designs to suit their carefully curated ecommerce wares.
Digital printing for packaging offers low minimum order quantities at a reasonable cost, unlocking the opportunity for small businesses to build their unique brand and enhance the consumer experience with boxes as unique as the product itself.”
But as with everything, there are always negative impacts. It is argued that there is a potential for an increase in packaging waste as ecommerce relies heavily on this. As we have learnt from Domino, this doesn’t hugely affect the smaller businesses, which means that we are playing our part to reduce the carbon footprint. However, retail giants, such as Amazon and eBay, use a considerable amount of packaging for a small item. This ultimately leads to significant waste, although the packaging we do receive can be recycled.
We all know that to become more sustainable, when purchasing products online, it’s not just the packaging but the shipping and logistics of receiving the item. Ecommerce heavily relies on long distance shipping and delivery services, which generate significant carbon emissions, especially if products are shipped from international warehouses. However, Amazon have released information on how they are making deliveries more sustainable throughout the UK.
A spokesperson from Amazon said, “As part of our commitment to sustainability, Amazon is making millions of deliveries on foot or using electric cargo bikes across the country. Many Amazon customers in London, Manchester, Glasgow, Belfast and now Norwich will receive packages delivered by more sustainable modes of transportation thanks to a series of new ‘micromobility’ hubs located in these cities, as well as many others across the world.”
“Millions of UK deliveries each year will be made from these hubs as part of Amazon’s commitment to reaching net-zero carbon by 2040. To achieve this, we are planning to invest €1 billion in the electrification and decarbonisation of our transportation network across Europe
through innovations like micromobility hubs, which are now operational in more than 40 cities across the continent. The investment includes £300 million in the UK alone and aims to promote innovation in the logistics industry. It will also encourage the development of public charging infrastructure, which will be key to helping the transportation sector reduce carbon emissions.” (Reference – www.aboutamazon.co.uk/making-amazon-deliveriesmore-sustainable)
However, when purchasing a product online, we sometimes buy more than we need (sizing, colour etc.), with the intention of returning the unsuitable items. This is another barrier as typically ecommerce has a higher return rate than traditional retail. Processing the returns leads to additional shipping, repackaging and waste when returned goods cannot be resold. However, there are occasions when businesses have accepted our refund request and tell us to keep hold of the item, which leads to loss of revenue, but contributes heavily to lowering carbon emissions.
In conclusion, we have been educated in how Domino and Hugo Beck are helping combat the problem regarding packaging. We also know that Amazon and eBay have made huge steps to becoming leaders in promoting a healthier planet and becoming more eco-friendly. However, we are also aware that ecommerce generates significant, potential waste and that a returns process can cause an increase in carbon emissions. Personally, I find that ecommerce will be the way of life soon. We are finding solutions to the problems of ecommerce; for example, we are now living in a world where electric vehicles and drones are delivering parcels, and it won’t be long until they figure out a way to use drones to collect the unwanted items, all aiming at reducing our carbon footprint and lowering emissions leading to a greener planet.
Being ice, snow or rain is in the nature of water.
Without well-designed packaging, new products become almost invisible on crowded retail shelves. Eye-catching graphics, colors, shapes, sizes, finishes, and functional features can provide the shelf impact to set the product apart and encourage the consumer to buy it.
Sustainable materials and processes also play a role as consumers and legislators push brand owners to reduce their carbon footprint and support a circular economy. Sustainable packaging minimizes or eliminates plastic, is recyclable, contains recycled content, is derived from renewable sources, can be reused or refilled, reduces carbon footprint, and/or is compostable.
Sustainability and product differentiation work hand in hand. For example, flexible packaging can attract attention to products traditionally found in rigid containers while shrinking their carbon footprint. Mesmerizing metallic and finger-pleasing tactile finishes can enhance appeal without affecting package recyclability.
Whatever sustainable packaging format is chosen, it should provide clear instructions about proper disposal practices, recycling protocols, and the environmental benefits of the materials used. Third-party certification of environmental claims also should be considered to prevent accusations of greenwashing. Transparent communication about a brand’s sustainability journey is vital. Sharing the environmental impact of packaging choices, production methods, and partnerships enables brand owners to build trust and generate sales because consumers like to support companies whose values align with their own
Sustainable processes and packaging cannot be achieved in isolation. Manufacturers, suppliers, retailers, and other stakeholders benefit when working together to optimize designs, explore
materials, and streamline packaging production. Developing and adopting more sustainable innovations for packaging will differentiate products, reduce carbon footprints, meet corporate goals, satisfy consumer and regulatory demands for less waste and more resource conservation, and help address climate change.
Brand owners will be able to find everything they need to design a sustainable package, launch their product, and scale up production at PACK EXPO International (Nov. 3–6; McCormick Place, Chicago), particularly at two new show features, Emerging Brands Central (Booth W-20049) and Sustainability Central (Booth W-21020). Attendees also can identify resources via the PACK EXPO Sustainability Solutions Finder and by looking for the PACK EXPO Green icon at exhibitor booths and in the lists of exhibitors and educational sessions.
As the world’s most expansive packaging and processing industry event in 2024, PACK EXPO International will feature 45,000 attendees from consumer packaged goods and life sciences companies worldwide and 2,700 exhibitors offering solutions to today’s biggest manufacturing needs from an intersection of industries in 40plus vertical markets. For more information and to register, visit packexpointernational.com.
For more information and to register, please visit: www.packexpointernational.com
As Emily Gambrill looks into innovative start-ups, there are so many innovative start-ups which are aiding our collective effort to becoming more sustainable. Whether it be a company which focuses on sustainable fashion or clean energy, there are new businesses being created with sustainability at the core.
Let’s start with LignEasy; they are a bio-based materials startup business which has just secured a €1m investment from EIT InnoEnergy. They have said that this capital injection and connection to EIT InnoEnergy’s ecosystem will support rapid scale up of the cleantech company.
LignEasy’s innovative technology is designed to reduce the carbon footprint associated with the pulping and chemical industries. Each year, over 15 million tons of lignin, a natural polymer that is one of the main constituents of wood, are burned by European kraft pulp mills for energy. Instead of burning this valuable resource, LignEasy’s patented technology separates lignin for use in highvalue applications such as plywood, construction materials, bio-components in plastics and packaging, providing sustainable alternatives to fossil-based products.
In the plastics sector alone, achieving the net zero target by 2050 will require an annual production of 100-230 million tons of bioplastics, compared to the current global production of just 2 million tons. LignEasy’s technology is poised to play a crucial role in meeting this substantial demand for sustainable materials.
Jonas Nordlund, Investment Manager at EIT InnoEnergy Scandinavia, commented: “We believe that LignEasy will play a significant role in decarbonising multiple industries, and we are delighted to welcome them into our portfolio. Their innovative approach to lignin separation not only addresses the significant wastage in kraft pulp mills but also opens up new avenues for sustainable bioproducts, transforming lignin from a waste product into a valuable resource.”
Juho-Matti Karpale, CEO at LignEasy added: “This investment marks a major milestone for our company and one that will help us to scale up our efforts to decarbonise the pulp and chemical industries. There are currently major issues with lignin wastage; a technology gap in achieving separation sustainably; and a pressing need to provide the chemical industry with eco-friendly alternatives to fossil-based raw materials. Our technology delivers solutions to these problems, and with access to EIT InnoEnergy’s ecosystem, we are now better placed than ever before to deliver them to the market.”
Packmatic, a Berlin-based digital packaging marketplace and one-stop shop for product companies seeking to optimise their packaging processes, has successfully raised €15 million in a Series A round led by EQT Ventures with participation from HV Capital, xDeck, and high-profile angel investors. The fresh capital will support Packmatic’s continued expansion in Europe, funding additional investment in software as well as the acquisition of top industry talent to help propel the business to its next stage of growth.
Matthias Geiss, Co-Founder and Managing Director at Packmatic, commented: “The packaging market has long been overlooked and underserviced – packaging is integral to supply chains and yet the sourcing process is slow and disjointed, which is especially painful for SMEs.
“Packmatic’s data-driven platform delivers meaningful cost savings and efficiencies to customers, while helping them to meet their environmental goals. With demand for responsible packaging solutions rising rapidly as businesses race to decarbonise across every stage of the value chain, Packmatic is promoting industry change with a solution that is cost-effective, efficient, and helps companies to reduce their plastic and carbon footprint.”
Rania Belkahia, Partner at EQT Ventures added: “The European packaging market boasts an impressive valuation, but remains opaque, fragmented, and crucially, largely non-digital. Packmatic’s platform provides a unique solution– a cost-effective, fully digital marketplace championing the shift to low-carbon packaging. “We’re excited to be partnering with founders Matthias, Jonas, and Paul, and believe Packmatic’s business fundamentals could not be better aligned with the current macro environment. With pricing pressures rising on companies in every industry and sustainability at the top of the global agenda, the company’s tech platform is perfectly poised to disrupt the market and become a category leader.”
Along with LignEasy and Packmatic, there are many other start-up businesses which are striving towards being more sustainable. Let’s look at start-ups that help to make our planet a greener place to be. For example, Climeworks’ focus is to direct air capture of CO2 from the atmosphere. Climeworks uses advanced technology to remove CO2 from the air and store it underground, helping to mitigate climate change. Climate change is affecting us now more than ever with the rise in adverse weather conditions all over the globe. This is an effective way of providing a solution to the climate change problem. Another company striving to provide a planet which can be more eco-friendly is Form Energy, whose focus is on long-duration energy storage solutions. Form Energy provide cost-effective storage for renewable energy, enabling a more reliable and sustainable energy grid. We look at all the new houses which are being constructed all over the UK, most of them will have a solar panel on them. This is aiding the government’s efforts with producing renewable energy and sending any surplus energy back to the grid. The efforts of homebuilding companies are only just scratching the surface of what we are achieving.
Now we turn our heads to Impossible Food, a company which is reducing the environmental footprint by creating plant-based alternatives to meat. To add to this, there is another company called Plenty whose main aim is on indoor vertical farming. Their focus is producing pesticide-free, sustainable grown crops using less water and space compared to traditional farming. This is good; we have more space to enjoy the fresh air we get from the outside and we don’t have to use heavy machinery to plough the fields, which all
contribute to dirty air and ultimately higher carbon emissions. Not only are businesses providing products which are manufactured in a more sustainable way, but there are also platforms which help companies reduce and track their carbon footprint. It provides companies with software to measure, manage and reduce their carbon emissions, helping them meet sustainability goals. Fintech, another business operating in a similar way, is s sustainable investment platform with the idea of allowing investors to align their portfolios with their environmental and social values by focusing on companies with strong environmental, social and governance ratings (ESG).
There is no denying that these start-ups mentioned above are innovative. They all focus on reducing environmental harm, creating clean energy in more efficient ways and contribute to solving global environmental issues such as climate change. We can’t speak for everyone, but as consumers we are finding ourselves increasingly looking for brands that align with their values, specifically start-ups which are driven by sustainability which have a strong, resonating brand story.
However, start-ups can run into many risks, and it can be difficult to scale. For example, most business will require investment, and depending on the size of the start-up, can be huge and costly. Also, they haven’t been trading for too long and the market is highly volatile and scaling in their business sectors can prove difficult. To round off these points, start-ups rely heavily on government incentives, grants or policy change to make their business models viable. Changes in political leadership or policy direction can significantly impact their growth.
This article shows how innovative start-ups can offer groundbreaking solutions to environmental problems, create significant environmental impact and help businesses track and reduce their carbon footprint. Furthermore, we have also learnt that these businesses require big investments, regularly in excess of £1 million, to get off the ground. This is a major risk for the investor, but as we have seen across the business sector, cash injection for a business striving towards an eco-friendlier planet, is positively altering the way products and services are provided to ensure a greener world.
More than ever, we are seeing that a lot of the products that we get from the shops is derived from recycled materials. Although this is a good way of using materials which have not been made from raw materials which are becoming scarce, there are disadvantages to using them.
Using recycled materials is surely the way forward, it helps to promote a greener planet, it is more sustainable and we’re not using raw materials to create a product which can be created by recycling other materials. Here at SPN, we have received news that Walkers are rolling out a new packaging made with recycled plastic. The new packaging is made with 50% recycled plastic which has been sourced using a mass balance approach. This means buying and using sufficient mass-balanced recycled plastic material to eliminate 200 tonnes of fossil-based plastic across Sunbites packaging by the end of 2025.
It is the latest in a series of packaging innovations from Walkers which has seen the brand recently launch new paper outer packaging for the entire Walkers Baked range and roll out a cardboard design for Walkers 20-bag multipacks. The launch forms part of PepsiCo Positive (pep+), Walkers’ parent company’s health and sustainability plan, which includes an ambition in Europe to eliminate virgin fossil-based plastic in crisp and snack bags by 2030.
Gareth Callan, Sustainable Packaging Lead for PepsiCo UK said: “The Sunbites transformation marks our ongoing commitment to offering products that are better for both people and planet. We’re proud of the progress we’ve made so far to reduce the fossil-based plastic we use and meet growing demand for healthier snacking options without sacrificing taste.
We’re working hard to reinvent ourpackaging. To help us do this at scale, we are urging the UK government to recognise the role that chemical recycling and other emerging mechanical technologies could play in creating demand for food-contact flexible plastics –including the modification of the Plastic Packaging Tax to stimulate a circular economy for packaging in the UK”.
“Sustainability is critical to the future of our industry, and we are committed to creating even more innovative products to reduce our impact on the environment and support the circular economy.”
Speaking for producers, by using more recycled materials in products as well as packaging, they can contribute to a more circular economy which in turn reduces the impact for climate change. Stephen Kapantais, Director of Technology, Rigid Plastics at Novolex said “We are proud to add to our growing number of products manufactured with recycled content. Sustainability is critical to the future of our industry, and we are committed to creating even more innovative products to reduce our impact on the environment and support the circular economy.”
We are also seeing that governments and organisations around the world are pushing for more sustainable practices in sectors such as construction, packaging and plastic recycling. For example, Scotland recently passed a tax on aggregates to promote the use of recycled materials in construction. Now, the question is whether this can be recycled and used again without tampering with the quality of the product too much. Concrete, which raises significant sustainability concerns, can be recycled indefinitely but in different forms. It can be crushed and reused as aggregate in new concrete or as a base material for road construction. This is argued that recycled concrete may not have the same strength but comparatively, recycled concrete can be less expensive than traditional concrete due to lower material costs and the potential reduction in landfill fees associated with disposing of it.
Like with most recycled materials, the initial costs can be more expensive, but it can provide long-term financial benefits.
Not just for materials such as concrete, but the construction industry are also using used paper bags to help improve circular economy. Mondi, a global leader in sustainable packaging and paper, has cofounded an alliance to improve the circularity of used paper bags in the construction industry. The Spain-based alliance, called Paper Sacks Go Circular Spain comprises of 12 European companies from the full value chain including Mondi. Paper Sacks Go Circular Spain is an alliance of companies that share a common interest in closing the loop and building a circular economy for paper bags in Spain. Starting with paper bags for construction materials, the coalition will look for synergies with other construction and demolition waste streams to increase volumes and achieve economies of scale. It aims to improve the recycling of paper bags used for construction materials such as cement, plaster and insulation, balancing the sustainability and economic aspects, and is expected to have a positive impact on the industry’s overall business model.
Carlos Martinez Ezquerra, Circular Economy Manager at Mondi Flexible Packaging, says: “This initiative demonstrates Mondi’s commitment to collaborating with industry partners across the value chain to increase recycling rates for used paper bags. It creates a scalable approach for the rest of Europe and other industries, leading to a reduction in waste management costs, a significant increase in the valorisation rate, and supports transparency and traceability of the circular economy. We are proud to be one of the founding initiators.”
As consumers, we are finding that the more and more of the packaging that we have in our household is formed from recyclable materials. This is great, as businesses are playing their part in becoming more sustainable and helping to battle climate change. Also, this is great as a consumer as we know that most of the packaging we receive is made of recycled materials and therefore can be recycled. However, like most things, it can only be recycled so many times before it becomes unusable or downcycled. For example, paper can be recycled up to 5-7 times as each time it is recycled, its fibers shorten and
weaken. Plastic is even less than that at 1-3 times before the polymer chain shortens, reducing their strength, flexibility and colour clarity. On the flip side of this, materials such as aluminium and glass can be recycled an unlimited amount of times without losing their quality, but this does prove a cost issue for the producer.
We all try to be as cost effective as we can, using recycled materials can pose a financial problem. In some cases, recycled materials can be more expensive than virgin materials due to the costs of sorting, cleaning and processing. Price increases in these areas is due to convenience of creating something from scratch rather than using multiple process and taking more time to create the same thing. It is also argued that focusing heavily on recycling can distract from other, more sustainable solutions like reducing consumption, reusing products and designing products that last longer. We can all agree that we would like our products to last longer, it saves on cost and contributes to a greener planet, but in reality, we know that this won’t happen. Nothing lasts forever and this is why we look at creating products which use recyclable materials to ensure that what we can be as eco-friendly as we can.
In conclusion, using recycled materials can be expensive and eventually, the products manufactured from recycled materials can only be recycled so many times before the lose their quality. Also, there are financial implications that we are aware of and by creating a new product using raw materials is arguably less expensive. However, as we have seen from Walkers and Mondi, there are businesses that are using more recycled materials to help reduce their carbon footprint. We have seen that there are also products which can be recycled indefinitely which helps to promote a circular economy, but we must not see this as the only solution to the climate change issue, this is a only a part of the larger picture to sustainable production and consumption.
“We are proud to be one of the founding initiators.”
The packaging industry is an integral part of our everyday lives, with a global value exceeding $1 trillion. On a daily basis, billions of packages are being used worldwide. However, as climate change concerns intensify, consumers are becoming increasingly environmentally conscious and exerting pressure on companies to adopt sustainable practices and reduce their environmental footprint.
Equally, ensuring product safety is also paramount, where packaging plays a pivotal role in safeguarding products throughout their entire journey - from shipping to handling and storage. This emphasizes the urgent need for environmentally friendly solutions and underscores the importance of utilizing sustainable packaging. One such company leading the way for sustainable packaging is ACTEGA, a global company of the chemical group ALTANA – that offers a comprehensive range of specialty chemicals and solutions for the packaging and print industry, spanning numerous sectors of the market, including flexible packaging and labels, folding cartons, or metal packaging.
In an ever-changing world of packaging, sustainability is no longer a choice but a mandate across the value chain, driven by factors like environmental awareness, regulatory compliance, and the push to minimize packaging waste. Sustainability has transitioned from a luxury to a necessity for brand owners aiming to maintain competitiveness in their sector. Industry leaders are grappling with numerous critical factors that will influence the future of packaging, yet one factor stands out: regulation.
Operating within a complex regulatory landscape, the packaging industry faces a myriad of requirements regarding specifications, recyclability, primary use, labelling, traceability, raw material sourcing, and disposal. However, the surge in packaging usage, coupled with inadequate reuse and recycling rates, impedes the progress toward a sustainable, low-carbon circular economy. In alignment with the new approach to products, The European Green Deal proposed measures to reduce packaging waste, encourage reuse and refill, and ensure that all packaging is recyclable by 2030. The EU’s draft Packaging & Packaging Waste Regulation (PPWR) introduced in 2022 marks the start of a legislative process
set to culminate in the final version by 2024, with implementation possibly commencing in 2025. This ambitious regulation is poised to have profound implications across various packaging types and their associated materials, making it one of the most impactful regulations in this domain. As the PPWR leads the way in reducing packaging pollution and promoting a circular economy for packaging that covers the entire life cycle of packaging, companies must consider how they can adapt and evolve to meet the changing landscape of the packaging industry.
Dennis Siepmann, Head of Sustainability, ACTEGA, commented, “The future of packaging is looking increasingly regulated, and companies that want to succeed will need to stay ahead of the curve. As regulations in our industry continue to increase, they drive us towards greater sustainability. At ACTEGA, compliance is merely the foundation; we’re dedicated to driving impactful change today while also fostering a sustainable future for the long term.”
Notably, regulations such as PPWR greatly influence the design and composition of packaging. Recycling will be the name of the game in the packaging industry. Therefore, key considerations will be factors like “separability,” identifying harmful substances that affect reuse and recycling, and providing recyclability assessment information. Plastic packaging components must meet specified minimum percentages of recycled material for their respective types by 2030. ACTEGA prioritizes packaging’s life cycle and recyclability. The company has been a strong advocate for the circular economy model, which identified and implemented five key tactics for creating a successful circular economy: recycle, reduce, dispose, replace, and degrade. These tactics guide the journey to transform their production system into a regenerative and restorative one.
Dennis Siepmann, Head of Sustainability, ACTEGA, said: “At ACTEGA, we placed great emphasis on the life cycle of packaging and its recyclability, and we continue to do so. In line with our commitment, we have made a forward-thinking investment by acquiring new testing equipment at our Cinnaminson site in the USA. This initiative allows us to evaluate the recyclability of paper packaging effectively and provide our customers with well-informed statements.” At their new recycling test facility, ACTEGA assesses factors like fibre recovery and contamination based on current and upcoming standards. As a member of 4evergreen, ACTEGA participates in shaping recycling design guidelines. This effort aids in advancing knowledge on the recyclability of fibre-based packaging, offering valuable guidance to stakeholders, including brand owners, throughout the value chain.
Sustainability in the packaging world extends far beyond recycling
Strict regulations mandate the use of recycled plastics in packaging, further reducing the environmental impact. Yet, the commitment to sustainability extends far beyond just recycling; the packaging sector will be encouraged to explore alternative options, such as refillable and reusable packaging, offering consumers environmentally friendly choices. Another significant driver of the sustainability of the packaging sector is the emphasis on data-driven sustainability benefits of packaging products. Consumers are increasingly seeking transparency and data that demonstrate the sustainability benefits of the products they purchase. Therefore, it is crucial to collect carbon footprint data at the product level for brand owners when choosing packaging. With companies like ACTEGA leading the way, manufacturers will be able to offer this data to brand owners, simplifying the process of measuring their carbon footprint comprehensively.
ACTEGA recognizes the importance of becoming more sustainable at the product level while reducing their carbon footprint at the operational level. As part of their ongoing project, the carbon footprint of their solutions is being investigated; this involves working closely with their suppliers and partners to ensure better data availability. As such, the company is already experiencing a rise in customer inquiries about accessing their company’s sustainability data, including information on emissions, environmental programs, and CO2 data for their products.
It’s not difficult to anticipate stricter requirements not only at the product level but also regarding emissions at production sites. The Corporate Sustainability Reporting Directive (CSRD) requires among others reporting on sustainability aspects of economic activities, encompassing emissions from gas and electricity consumption. With these new requirements, brought together under the umbrella of a double materiality assessment, companies should evaluate the impact of their business activities on the environment and society, and how sustainability factors and societal changes affect their business both operationally and financially. In response to this, ALTANA conducted a comprehensive materiality assessment. As part of the ALTANA Group, ACTEGA is fully aligned with ALTANA’s materiality topics.
Commenting on Altana’s new materiality assessment, Dennis Siepmann said: “ACTEGA has a long-standing commitment to sustainability, and we have embedded it into our solutions and business practices, fostering a cultural norm throughout the organization. Our focus on sustainability is driven by its understanding of economic, ecological, and corporate social responsibility factors, which is mirrored in ALTANA’s mission statement. ALTANA’s new assessment on the materiality topics has enabled us to review the most significant sustainability issues in our business activities that also influence the individual divisions from a sustainability perspective, including sustainable products and innovations, emissions from products, and safety aspects.”
Working towards reducing their carbon footprint is also crucial for ACTEGA. Taking ambitious steps to decrease Scope 1 and Scope 2 emissions is essential for demonstrating a commitment to a greener future. Generating electricity for their production plays a key role in reducing emissions. The photovoltaic system at the Bremen site demonstrates how companies can take environmental responsibility. The company has commissioned a new 1,000 kWp photovoltaic system on the roof of the 7,600 m² building in Bremen, expected to generate over 850,000 kWh of electricity annually. The system covers the entire permitted area of ACTEGA’s new building, contributing to their sustainability efforts.
In addition to planting the photovoltaic system at its Bremen facility, ACTEGA has transitioned to catalytic exhaust air purification at its Grevenbroich site. This strategic shift is resulting in an annual reduction of approximately 500 tons of CO2-equivalent greenhouse gas emissions.
Dennis Siepmann said, “By prioritizing sustainability efforts, we not only contribute to protecting the planet but also demonstrate our dedication to being a responsible and forward-thinking business. At ACTEGA, we consistently examine our practices and make changes where necessary. This ongoing commitment drives us to continually assess and optimize our portfolio for greater sustainability.”
Pioneering product assessment and optimization in pursuit of sustainability
Innovation in product development is key for the packaging sector, indeed, for all industries, particularly in the context of addressing climate change and reducing carbon footprint. In today’s dynamic business landscape, incorporating ESG factors into the core of strategic decision-making is essential. For packaging companies, product evaluation and optimization through an environmental lens are increasingly significant, marking a pivotal step towards greater sustainability. Collaborating with companies dedicated to advancing product development through an environmental perspective enables brand owners to align their packaging with evolving ESG standards, enhancing readiness for the future more effectively.
ACTEGA conducts systematic sustainability assessments as part of its R&D process to evaluate the sustainability benefits and challenges of product portfolios and the R&D pipeline. This involves assessing factors like avoidance of hazardous
chemicals, eco-label criteria, and brand owner requirements, as well assustainability aspects such as PCF reduction, recycling advantages, and energy efficiency improvements. By integrating controlled sustainability assessments into new product development, ACTEGA identifies the opportunities for sustainability enhancements early on. In addition to sustainability evaluations during R&D, the current product portfolio undergoes analysis using similar criteria. Different product families and applications are reviewed for their impact on energy efficiency, waste reduction, and greenhouse gas emissions. By doing so, ACTEGA’s ultimate aim is to create a comprehensive overview highlighting areas for sustainability enhancement and recognizing existing high performers in sustainability within the product range.
“At ACTEGA, our mission is to create value for our customers, employees, and society as a whole. We’re dedicated to creating innovative solutions that not only improve the quality of daily life products but also foster sustainability and growth for our customers,” added Siepmann.
“We’re proud to be at the forefront of exciting innovation that serves as primary examples for the industry that contributes to a greener future. ACTEGA is continuously developing sustainabilitydriven solutions and products targeting downstream stages of the value chain. Within this intricate regulatory environment, we’re propelled towards enhanced sustainability practices. ACTEGA not only meets current regulations but also aims to surpass them in pursuit of its sustainability objectives. We believe in the power of collaboration and continue to support brand owners to achieve their ambitious sustainability goals through our innovations and know-how for a sustainable future,” concluded Dennis Siepmann.
In today’s packaging industry, sustainability is no longer just a trend—it’s a necessity. With increasing consumer demand and stricter regulations, companies must focus on reducing waste, reusing materials, and maximizing recyclability. Greiner Packaging, a leader in sustainable packaging solutions, has made significant strides in these areas, particularly through its innovative use of post-consumer recycled (PCR) materials, optimized designs, and advanced recycling processes. Here’s a closer look at how Greiner Packaging is contributing to a greener future.
Post-consumer recycling (PCR) is a cornerstone of sustainable packaging. It not only diverts waste from landfills but also reduces the need for virgin materials, conserving energy and raw resources. At Greiner Packaging, incorporating PCR materials, such as recycled polyethylene terephthalate (r-PET) and recycled polypropylene (rPP), has proven to be a key element in reducing the carbon footprint of packaging production. For instance, using r-PET can reduce CO₂ emissions by up to 70% compared to using virgin PET. This significant reduction in emissions, coupled with its ability to meet food-grade standards, makes r-PET a particularly attractive option for food and beverage packaging.
In addition to using recycled materials, Greiner Packaging has focused on making its packaging more recyclable through innovative design. One example is the K3® solution, a cardboard-plastic packaging system with a new tear-tab that simplifies separating the materials for recycling. A recent enhancement introduced the K3® r100 cup, which further facilitates recycling by automatically separating its components during waste management. This ensures that each material can be properly processed and reintegrated into the production cycle. The optimized design aligns with the principles of the circular economy by ensuring materials can be efficiently returned to the recycling stream, minimizing waste and extending the lifecycle of packaging components.
Increasing recycling efficiency requires continuous innovation, especially in how materials are processed. One of Greiner’s
recent developments in this area is the enhancement of washing techniques, which now enable the deinking of printed polypropylene (PP) and polystyrene (PS) cups. This advancement helps to address the challenge of contamination in post-consumer recycled (PCR) materials, particularly for food packaging, where safety and hygiene are paramount.
Legislation is also playing an increasing role in pushing the packaging industry toward sustainability. The upcoming EU Plastic Packaging Waste Regulation (PPWR) highlights the importance of using recycled materials and reducing plastic waste. Greiner Packaging is already ahead of the curve, aligning its practices with new regulatory requirements while continuing to innovate sustainable solutions.
For example, the PPWR will enforce stricter regulations on material recycling rates and limit the amount of virgin plastic used in packaging. Greiner’s commitment to recycled content, alongside its investments in recycling technologies, positions the company as a leader in navigating these changes and helping its clients meet their regulatory obligations.
Discover Greiner Packaging’s sustainable packaging solutions at the following events:
• Pack Expo, Chicago, November 3-6, Booth W-22013.
• Sustainable Packaging Summit, Amsterdam, November 12-13, Booth 4
For more information, please visit: www.greiner-gpi.com
From the increasing scarcity of resources to the need to reduce products’ carbon footprint, it is vital that Albéa and the entire industry focus on expanding the use of post-consumer plastic, obtained through mechanical recycling (mPCR*).
This is a prerequisite for expanding the use of responsible packaging. Nevertheless, this solution is not without consequences for the entire value chain. Our objective is not just to ensure product quality, but to do so while generating as little production scrap and post-consumer waste as possible. At the crossroads of these issues lies the use of mPCR, which refers to recycled materials derived from products that are consumed, discarded, then regenerated into new material(s) through mechanical recycling. However, the use of mPCR is not yet a legal requirement. Demand is therefore purely voluntary at present and considerable physical and R&D investment is required to adapt to these new raw materials, from molds to production lines.
The compromises inherent in the expansion of mechanical recycling
Using mPCR means making a few compromises, particularly on aesthetics. The quality of the mPCR depends on the quality of the sorting process. It may contain impurities or have minor defects that can have an impact on the final packaging. More generally, packaging made from mPCR varies somewhat, as the material is less pure. Perfectly uniform packaging and zero production waste are therefore impossible, a particularly sensitive issue for products positioned in the luxury market. Paradoxically, the more we want to develop responsible packaging, the greater the risk of packaging defects—even minor ones— and, by extension, scrap. It is one of the occasional consequences that the entire value chain needs to accept to develop sustainable solutions that will keep improving.
To address these challenges, we need to educate everyone, from our customers to end consumers. First, our customers need to accept these facts so that together we can contribute to the muchneeded development of sustainable solutions. Do products with minor defects really need to be destroyed when the initial goal is to reduce waste, not to increase it? All companies’ functions therefore need to tackle these subjects for “recyclable” to become synonymous with “desirable”—and reasonable. We also need to educate consumers, so they understand that packaging made from mPCR is likely to have a few cosmetic defects that do not in any way affect its quality or usability.
Aware of the need to rise to these major challenges, we are actively making progress, thanks to increasingly sophisticated sorting technologies as well as our suppliers’ enhanced expertise and equipment.
Flexible packaging has many advantages; it’s lightweight and portable, protects the product from moisture and therefore increases its shelf life as well as offering convenience with options such as zippers, spouts and sliders. All this leads to a lower environmental impact and therefore creating a greener planet. On the flip side of that, flexible packaging does have its concerns. For example, multi-layered flexible packaging is difficult to recycle because separating the materials is a complex process. Also, it is a known fact that flexible packaging does not provide excellent protection for many items that require extra strength or rigidity.
Let’s look at Debatin; their packaging solutions are now becoming even more sustainable in advances in flexible packaging. Household waste streams are now best used for PCR films but are difficult to recycle. Anton Debatin GmbH and PreZero Flexible Packaging GmbH are making packaging solutions more sustainable through intelligent recycling.
Anton Debatin GmbH is launching its next sustainable innovation in collaboration with PreZero Flexible Packaging GmbH. For years, the Bruchsal-based packaging experts have been associated with sustainable packaging solutions, some of which use post-consumer recycled (PCR) film. “We have been using films made from PCR material for years for a large proportion of our products, which contain more than 80% PCR,” says Debatin CEO Thomas Rose. Thanks to PreZero’s expertise, the new end-product contains 60% PCR material, with 50% coming from materials collected through the household recycling system, including plastic packaging and mixed recyclables. “Thanks to its innovative recycling technology, PreZero can incorporate household waste streams into the production of PCR film, even though this type of raw material is often highly contaminated and contains a variety of material combinations,” continues Thomas Rose.
Klöckner Pentaplast, a global leader in sustainability-focused food packaging solutions, has announced the launch of two new recyclable barrier flow wrap films: kp FlexiFlow® EH 155 R and kp FlexiFlow® PH 255 R. The fully recyclable pair can reduce packaging weight by up to 75% compared to alternative solutions, representing a significant leap forward in sustainable food packaging design.
“By designing our products with sustainability at the heart, we help food manufacturers to meet increasing consumer and regulatory demands without compromising on quality or efficiency. Our expertise at kp is the reason we’re able to do this so effectively.” said Francisco Quesada, Senior Commercial & Marketing Director, Flexibles, at Klöckner Pentaplast.
“As legislation and corporate sustainability initiatives continue to evolve around the world, these new barrier films further cement our position at the forefront of recyclable packaging innovation,” Francisco Quesada added. “By providing options in both PE and
PP, we’re ensuring that our customers can select the material best suited to their specific product requirements, and the recycling infrastructure of the markets they’re operating in. We’re not just meeting current standards; we’re anticipating future needs and providing solutions to drive the industry forward.”
Following on from what Klöckner Pentaplast are managing to produce, this further explains the positive impact flexible packaging has. In turn, this helps to extend the shelf life of food and perishable goods, reducing food waste.
SABIC, a global leader in the chemical industry, has joined forces with Lamb Weston, a major global brand owner and producer of frozen potato products, in a closed-loop process designed to create lowweight sustainable packaging bags made with a thin coextrusion film structure. At least 60% of the packaging is made with polymer using bio-feedstock from used cooking oil (UCO). Sebastiaan Besems, Vice President Commercial EMEA from Lamb Weston comments: “Distributors, retailers and consumers have become increasingly conscious of their environmental impact and show a growing preference for more sustainable packaging. We have anticipated this trend and developed an industry-leading bio-circular retail packaging solution for our pre-fried frozen potato products that provides a highly responsible value proposition.”
packaging which is going to be more sustainable. As a reader, it feels so good to be reading about businesses which are trying to make a positive impact to the planet by creating practical solutions to the issues that we face today.
However, there are still issues that we need to overcome which are brought on by flexible packaging, and packaging in general. As mentioned in the Reuse v Recycling feature and earlier on, multi-layered flexible packaging which are composed of different materials, can be difficult to recycle. This is because everything must be separated and, unless consumer behaviour changes, this will always be a setback. But like I’ve said, to overcome this, we need to educate consumers to change their behaviour so that we can start building a brighter future for the younger generation. As we have learnt, flexible packaging is great for single-use or short-term applications, but it may not offer the same longevity or reusability as more durable packaging options like glass or metal. This then limits its lifecycle and increases the need for frequent disposal. As landfill sites mount, we are trying to stop this issue, but advances from innovative start-ups mean that we are on the way to solving this.
It is also argued that flexible packaging may not be suitable for all products. For example, products which require extra strength or rigidity, such as heavy or fragile goods, that need more robust protection. In addition to this, some consumers perceive flexible packaging as less durable compared to rigid alternatives. The lightweight materials may seem flimsy, making the product inside appear lower in value. The solution to this issue seems simple enough though; we only use flexible packaging for foods and products which do not require robust packaging. However, it would be beneficial to think of a way that we can ensure robustness with flexible packaging because of the sustainable properties that it offers.
We see a lot of big businesses now using flexible packaging for their products. It goes without saying, advances are being made all the time in this sector and eventually all the challenges that were there will be eradicated. We can’t be naïve and think that this will happen overnight, we have a long way to go, but we are stepping forward in the right direction.
I, Emily Gambrill, investigate the world of caps and closures. We look at what businesses are doing primarily as writing about it is one of the best ways of ensuring that people are correctly educated and that the information surrounding recyclable products is spread widely.
Let’s start with Berry Global. They have launched a tamper-evident pouring closure for edible oils, dressings and sauces, which combines consumer convenience and functionality with sustainability enhancements that improve its recyclability.
Fully compliant with EU regulations for single-use plastics, the new Pical Pouring Closure – part of Berry’s B Circular portfolio – features a special tamper-evident tab that drops inside the closure when the lid is opened for the first time. This ensures the tab remains with the pack so that all components enter the recycling stream. The snap-on neck finish also means that the bottle does not require an additional sleeve for tamper evidence.
Manufactured in HDPE, the lightweight closure is a one-piece design and of mono-material construction, making it fully recyclable where appropriate collection facilities exist.
Matthias Hammersen, VP Sales at Berry Global Consumer Packaging International Division, stated: “With our Pical closure, we have addressed consumer demands for both convenience and sustainability. The modern design offers comfortable handling and optimal pouring performance, while its lightweight mono-material construction and retained tamper-evident tab ensure it is easy to recycle.”
PulPac, the innovator behind Dry Molded Fiber technology, and PA Consulting (PA), the global innovation and transformation consultancy, are excited to announce the development of Dry Molded Fiber bottle caps now testing with the Bottle Collective.
This innovation marks a significant leap forward for fiber-based packaging, offering brand owners a sustainable alternative that meets consumer demands for environmentally friendly productsThe introduction of fiber-based caps is a game changer for the packaging
industry, supporting the transition to higher fiber content across more packaging solutions. By replacing traditional plastic caps with those made from Dry Molded Fiber, companies can significantly reduce their environmental footprint while providing consumers with a more sustainable choice. This marks the first stage of innovative developments in fiber-based caps and closures from PulPac and PA, with an upcoming range to be unveiled in the near future.
“We are thrilled to introduce this new bottle cap as part of our ongoing work with the Bottle Collective,” said Jamie Stone, design, innovation and sustainability expert at PA Consulting. “With our latest innovation in bottle caps, we’re enabling the creation of entire bottles made from Dry Molded Fiber technology, offering a sustainable and scalable alternative to single-use packaging.” “We are just scratching the surface of this technology’s potential. Dry Molded Fiber products can be part of people’s lives in many ways, from a morning coffee on the go, to preparing the family dinner or serving a drink to long-awaited guests. Dry Molded Fiber can enhance these moments with sustainable, high-performing packaging solutions” said Sanna Fager, Chief Commercial Officer at PulPac.
Philip Fawcus, sustainable materials expert at PA Consulting, added “This bottle cap is not only a milestone in sustainable packaging but also a testament to the versatility and scalability of the Dry Molded Fiber technology. at the forefront of providing innovative alternatives that meet both environmental and market needs.”
The revolutionary technology developed by sustainability start-up Blue Ocean Closures to reduce plastics in packaging closures is now introduced to the market. The cellulose fiber cap on Great Earth products marks the epic start of commercialising the brand-new category of advanced, recyclable as paper closures.
Sweden based Great Earth is a producer of nutritional supplements with a vision to contribute to a good and healthy world. The collaboration with Blue Ocean Closures is motivated by a strong desire to create a better world and actively work with sustainability.
“In line with our vision, it is obvious for us at Great Earth to choose the most sustainable packaging solution. Fully implemented Blue Ocean Closures’ fiber screw cap reduces our plastic use by 2,6 tons per year and impacts carbon footprint. It is an important step on our journey towards increased circularity,” says Patrik Falk, CEO, Great Earth Scandinavia AB.
Furthermore, Blue Ocean Closures is bringing to market is a fiberbased packaging screw cap, that is biobased and recyclable as paper.
“For us to succeed with this groundbreaking move, away from fossilbased plastics, it is extremely important to have global brands onboard, with the ambition and ability to truly making a difference, says Lars Sandberg, CEO of Blue Ocean Closures. And he continues; “We are thrilled to announce our explorative partnership with Coca Cola’s EMEA R&D Center today, focusing on innovation to bring new and more sustainable products to use.”
In line with its ambitions to advance sustainable packaging while reducing the use of non-renewable material, and support its ambitious World Without Waste strategy, Coca-Cola is joining Blue Ocean Closures’ community of pioneering partners.
“We are excited to be part of the pioneer community and to help test and develop this innovation during its continued development. It fits both our sustainability strategy and our on-going exploratory work with future packaging technologies which may complement other, existing types of packaging in our packaging mix,” says Daphné Ronat, Packaging Engineer at the Coca-Cola EMEA R&D Center in Brussels, Belgium.
As we have read from Berry Global, PulPac and Blue Ocean Closures, there are ways to overcome the problems which caps and closures may throw up. They have explained how their products are made from recycled materials, are mono-material construction, which makes it easier to recycle, and derived from biodegradable materials. All these concepts are a fantastically innovative way of contributing to becoming more sustainable.
There are also many other companies which are shifting to recyclable materials such as polyethylene terephthalate (PET) and high-density polyethylene (HDPE) for caps and closures to minimise waste. Along with what we have read, all these materials are supporting the wider effort to becoming a greener planet. However, by sourcing and manufacturing these sustainable products, it can prove to impact the overall packaging costs.
Caps and closures play a significant role in raising awareness and brand responsibility. What I mean by this is that brands are increasing communicating their sustainability efforts regarding caps and closures to consumers, enhancing brand and loyalty and certifications and eco-labels help consumers identify sustainable products. This in turn drives demand for responsibly sourced packaging and clear understanding of how to safely dispose of caps and closures.
Along with the advances being made from companies regarding sustainable sourcing of caps and closures, the European Union will enforce mandatory tethered closures for beverages starting in July 2024. This legislation aims to reduce litter and improve recyclability. Specifically, Berry Global are investing in technology to produce these closures efficiently, emphasizing that tethered caps are a significant shift in packaging standards.
It is clear to see from the news we receive here at SPN, companies all over the world are aiding in efforts to make a cap more sustainable. This may seem like a small cog, but in fact it’s personally one of the most important parts in contributing to the recycling process. Consumers tend to throw the whole product in the bin as they are not sure of what can and can’t be recycled, so for ease and convenience, this is generally what is done. However, with clear labelling, increased communication and education, consumers will slowly change what they do so that we don’t impact the planet. Onwards and upwards is the way forward; it won’t be long until the recycling bin is overflowing!
We may confuse the terms Circular Economy and Circular Feedstock; however, they are two different concepts. Whilst Circular Economy is the term we use to describe an economic system aimed at eliminating waste and continual use of resources, Circular Feedstock refers to the materials that are reintroduced in the production process as a substitute for virgin raw materials. Here at SPN, Emily Gambrill delves into Circular Feedstock further.
To truly achieve circularity, lifecycle thinking is essential, ensuring the environmental impact of each stage in the design process is considered. This encompasses everything from raw material extraction, such as the petroleum oils used in virgin plastic production, to disposal.
Optimizing material use from the beginning is crucial, reducing the quantity of materials needed for packaging without compromising functionality. For instance, Amcor successfully reduced the PET required in a 12-ounce bottle by 13 percent while maintaining the necessary strength.
End-of-life management in the product lifecycle demonstrates a business’s accountability, taking ownership of the environmental impact their product has after sale. For example, Coca-Cola removed plastic labels from its bottles to enhance the recyclability of the product after use.
In the packaging industry, the development of biodegradable and home-compostable packaging has revolutionized the vision for the future. However, this progress must be approached with caution. Questions have been raised about the true compostability and biodegradability of these packaging solutions. Not everyone has access to commercial composting facilities or even a home compost heap. Furthermore, nearly one-third of Americans are unsure how to correctly dispose of compostable packaging and mistakenly place it in the recycling bin. While innovation is vital, it must also provide a credible circular solution to effectively address the current environmental and climate crisis.
Accredo Packaging, a leader in the development of innovative, more sustainable packaging solutions for the food and consumer products industries, has collaborated with Fresh-Lock closures, a brand of Reynolds Consumer Products, to introduce the first 100% biobased resin pouch with a zipper closure.
This pioneering product represents a major advancement in more sustainable packaging, addressing the growing demand for more environmentally responsible solutions, when compared to conventional packaging. Made from sugarcane-derived resin, the pouch comprises a fully renewable composition to help brands meet their sustainability goals, by lessening environmental impact. The development of this innovative packaging sets a new industry standard by balancing various factors, including sustainability, functionality, and performance, while providing brands with a powerful tool to help achieve their greenhouse gas (GHG) reduction goals. Initially targeted at the food sector, the biobased pouch also offers promising applications in industries prioritizing a more sustainable approach, such as cosmetics, personal care, and household goods.
Overcoming substantial technical hurdles in the pouch making was a key part of the process, particularly in adapting equipment to accommodate a single stream of sugarcane-derived resin. Unlike conventional packaging, which relies on multiple resin grades, this solution uses the limited grades of sugarcane resin to match the performance of virgin plastic. Achieving this milestone involved precise modifications to equipment settings - temperature, pressure, and cooling - to ensure the pouch met all performance standards, without compromising appearance or quality.
A range of new eco-friendly packaging materials made from onion skins and peelings is being created by an Oban-based startup, offering an alternative to fossil fuel-derived plastic products – a major contributor to household waste.
Up to 400kg of waste onion skins are produced per week[1], with the majority ground up for use as cattle feed, while UK households throw away an estimated 90 billion pieces of plastic packaging annually[2]. Renuka Ramanujam, HUID’s founder, said: “Onion skins are nature’s own form of packaging, protecting the onion below from harm and are a plentiful waste source. Yet, after speaking to various scientists I realised that no one was using them as a material and spotted a gap in the market for a new variety of eco-friendly packaging.”
Aineias Karkasinas, Sustainability Engineer at NMIS, said: “HUID’s creative use of onion skins minimises waste and is a great response to the current market need for sustainable packaging. It has been great to support the development of genuinely sustainable solutions and provide HUID with deeper insights into the environmental performance of its materials.”
Circular Feedstock offer numerous advantages, for example, it promotes using renewable materials rather than virgin resources which are becoming scarce, and it generally results in fewer greenhouse gas emissions and enables the reuse of waste materials. I know that this list is short, but this is just a handful of the wider advantages that Circular Feedstock provides.
On the other hand, it does have its limitations. To start with, Circular Feedstock requires advances in technologies, such as chemical recycling or bio-refining. These processes are not yet fully scalable or widely available, which contributes to limiting the immediate impact on industries. As we know though, technology is developing all the time and sooner rather than later, this will become an issue of the past, but saying this, there is still limited availability. The supply of high-quality Circular Feedstock is still limited in some regions, especially materials like certain plastics metals or specialised chemicals. Therefore, it can make meeting industry demand with recycled or bio-based feedstock challenging. Eventually, there will be a time where these materials won’t be so scarce as we will be making more and more of it. Essentially, this problem will be eradicated, but it will take time.
It is also argued that some recycling processes, particularly chemical recycling, can be energy-intensive and require significant amounts of energy to convert waste materials back into usable feedstock. If the energy comes from non-renewable sources, this can undermine the environmental benefits Circular Feedstock deliver. Along with this, it can be said that using complicated processes can be costly. Circular Feedstock does require high initial costs. It demands investment in technologies and infrastructure to process and utilize circular feedstock, and this can be difficult for smaller companies. The investment can also include costs for recycling facilities, supply chain adjustments and certification. Furthermore, the development and implementation of regulatory frameworks and certification systems can take time. Ensuring that Circular Feedstock meets industry standards and can be trusted by consumers can be complex. The hurdles put up by this can prove to be costly, as described before, with the demand for high investment. However, as with everything, costs decrease over time making it easier to manage once the concept is in motion.
As we have read in this article and the news we are receiving all the time, the initial high investment and advanced technologies is not deterring companies from making huge steps forward in this space. It seems like circular feedstock is the way to beating the problem surrounding the use of virgin raw materials, which is a big bonus as we all know that these raw materials are running out. It helps to contribute to a lower carbon footprint and circular feedstock is a key enabler of a circular economy, which is what every person and business is working towards. It is to be said, overcoming these hurdles will require not only investment, but innovation and collaboration across industries and governments to build a more sustainable future.
No
Selenis is a global company committed to creating innovative polyester solutions that address the growing demand for recyclability and eco-efficiency, especially in industries with short product lifecycles. As a leader in sustainable materials the Portuguese subsidiary of IMG Group, is driving innovation. Selenis prioritises product design that aligns with recyclability and circularity, reducing the reliance on virgin materials and emphasising the recycling of plastics within the closed-loop system.
Culturally the company has an inherent focus on putting customers at the centre of their thinking, through every touchpoint of company interaction. This demonstrates itself in the way that they have streamlined and defined their four eco-friendly pathways to products so companies can make choices based not only on performance but also on providing a responsible approach to the future and creating value to society – in a simple and understandable way. Selenis define their sustainable product pathways as:
With their unique recyclable properties, CE resins can be used in a wide range of applications, from packaging to textiles. As fully recyclable materials in PET RIC1 recycling stream, CE resins contribute to a circular economy by allowing materials to be reused after collected, minimizing future waste and promoting resource efficiency by multiple utilizations. Through continuous innovation, Selenis is developing new CE resin solutions that offer even greater environmental benefits.
Eco resins.
Made from up to 80% post-consumer recycled materials, provide a sustainable alternative to traditional plastics, guaranteeing the same virgin-like properties. By using Eco resins, brand owners can reduce their carbon footprint and contribute to a circular economy. These resins are certified recycled, ensuring traceability on this segregated recycling approach.
Clear resins.
Include up to 100% ISCC Plus standard certified mass-balanced content. By certifying to the ISCC PLUS standard, a globally recognised certification system, Selenis provides transparency to track certified sustainable content throughout the value chain.
Bio-based resin.
Aligned with Selenis vision of reducing the industry’s reliance on fossil materials, they have developed PET and PETG resins containing up to 30% bio-based content. This innovation has resulted in an up to 40% reduction in LCA (Life Cycle Assessment) compared to traditional fossil-based resins.
Underpinning these pathways is Selenis’s focus on accomplishing their decarbonisation strategy and recent commitment to setting science-based targets through SBTi. This is accompanied by their actions in making Life Cycle Assessments (LCA) as a key part, not only to their sustainability strategy, but also for product development, providing them with a detailed view of the environmental impacts of products, from raw material extraction to the point they leave their production sites. Since 2022, Selenis has been calculating the environmental footprint of their most significant products, and by 2023, had completed LCAs for the entire product portfolio using a cradle-to-gate approach. This approach, following ISO 14040 and ISO 14044 standards, allows them to focus on the environmental impact of PET resin production up to the point it leaves the facilities.
The use of spent organic materials has not yet reached an industrial level of market potential in terms of the value hierarchy in which its use for the production of pharma and cosmetics and food and feed are the preferred options, and where bioplastic and biopolymer production is a preferred alternative to the production of bulk chemicals, fuels, energy and heat, and, of course, landfill.
by Rosa González, leading researcher in Packaging at AIMPLAS.
This is the case of Brewer’s spent grains (BSG), the most abundant byproduct of the brewing industry. They are not seasonal and are available at low or no cost and produced in large quantities all over Europe, and have limited use as a feedstock. Although about 70% of this byproduct is currently used for animal feed and 10% for bioethanol production, 20% of it currently goes to landfill. BSG is also a promising candidate as a PHA feedstock due to its composition and the damaged state of its chemical structure after malting, which makes it more prone to enzymatic hydrolysis processes leading to sugars for fermentation by the biotechnology industry. Based on this concept, the BIOSUPPACK Project aims to deliver novel, cost-competitive and versatile bio-based packaging solutions based on PHA that demonstrate high-performance packaging of food, beverages, cosmetics and homecare products, as well as no environmental damage during and after use.
To comply with new legislation and consumer awareness, as well as industry requirements related to the need of biobased packaging to be balanced between cost and performance in order to compete with its non-biodegradable fossil-fuel-based counterparts, BIOSUPPACK is a European project coordinated by AIMPLAS and made up of a consortium of 17 partners from different European countries that have combined their expertise, know-how, technical capabilities and efforts to achieve a common objective. The project has received funding from the Bio-based Industries Joint Undertaking (JU) under the European Union’s Horizon 2020 research and innovation programme under Grant Agreement No. 101023685.
The project will help create a new value chain by connecting the
brewing industry with new biobased packaging solutions for the food and beverage, cosmetics and homecare industries. It will also connect the brewing industry with the biotechnology involved in the specific end of life foreseen for the packaging waste of the future, which will involve enzymatic recycling for the production of novel monomer units that will feed packaging material production in combination with BSG, thus closing the loop.
Considering this, the BIOSUPPACK Project involves technical, logistics, economic and social challenges that will be overcome and assessed during project development and implementation. Project success is necessary to make a real contribution to current regulations and policies related to the circular economy model, specifically those regarding plastics circularity and sustainable packaging.
The BIOSUPPACK Project is therefore expected to have great impact on EU bioplastics and end-user sectors, biorefineries, biotechnology industries and society.
been produced and formulated into compounds suitable for injection moulding and extrusion blow moulding technologies, thus allowing for production of the first set of rigid packaging prototypes at pilot scale, consisting of beer bottle displays and 125 mL bottles. The next steps involve the production of packaging prototypes at semiindustrial scale and validation. In parallel, several innovations have been assessed and are under optimization, such as the sorting efficiency of PHA-based waste, the use of novel enzymes for PHA degradation, and the use of plasma technology to improve the efficiency of BSG conversion and PHA waste degradation processes.
