SPN March 2022

Issue 22:2 - March 2022

SUSTAINABLE

PACKAGING NEWS

Taking the lead in sustainability

Food Packaging Sustainable solutions for food packaging and manufacturing

Reusable Packaging New sustainable innovations

Printing Inks Plastics E-Commerce

Vision-based technology Vimaan taps computer-vision for drone-based warehouse technology

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WELCOME TO SPN MAGAZINE

Welcome to

SUSTAINABLE

PACKAGING NEWS

Dear Readers,

March 2022

I hope this finds everyone keeping well and staying safe.

Despite the horrific situation in Ukraine, everyone we speak to appears to be staying positive and moving forward with their lives and their business aspirations.

Here at SPN we have also been very busy sourcing the latest packaging news from all around the world. These new developments bring fresh insights into sustainability and recyclability. For example, our cover story features the US company, Vimaan. This reveals technology that is revolutionising warehouse management by utilising drone-based computer vision. This new technology is saving huge amounts of energy whilst dramatically improving efficiency and reliability. Other interesting features cover new advances in water-based printing inks for food packaging, as well as a special piece on the age-old chestnut question of ‘whether to use Bottles or Cartons?’.

As always, there is a diverse range of subjects throughout this latest issue. In fact, due to popular demand our new regular feature, ‘Retail- Round-Up’ is more diverse and inclusive than ever.

In any event dear readers, we hope that everyone stays well and safe. In the meantime, we send our thoughts and condolences to all those who are caught-up in the untold misery and suffering that is unfolding in Ukraine, and pray that common sense will prevail.

Sincerely,

Issue 22:2 - March 2022

SUSTAINABLE

PACKAGING NEWS

Taking the lead in sustainability

Food Packaging Sustainable solutions for food packaging and manufacturing

Reusable Packaging New sustainable innovations

Printing Inks Plastics E-Commerce

Vision-based technology Vimaan taps computer-vision for drone-based warehouse technology

Director Editor Writer Designer

Kevin Gambrill Philip Yorke Dominy Jones Dom Thorby

linkedin.com/company/ sustainable-packaging-news/

news_packaging

Philip Yorke ( Editor )

spnews.com SUSTAINABLE PACKAGING NEWS

3

CONTENTS

Contents TOPICS

RESOURCE EFFICIENCY 13 Moelven - resource efficient packaging 14 GEW - UV systems Bottles V Cartons 18 Elopak Corrugated Packaging 20 DS Smith PRINTING INKS 22 Sirane Group 23 Pulse Roll Label Products 24 Domino - ink for food packaging

REGULAR FEATURES SUPPLY-CHAIN SLEUTHS

6 Vision-based technologies

RETAIL ROUND-UP

9 Ukraine support package 10 Fashion for the better 11 Celebrating a new milestone

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PLASTIC PACKAGING 26 UFlex flexible packaging 28 UK goverment investment E-COMMERCE 32 Amazon reducing waste 33 Syntegon FOOD PACKAGING 36 Huhtamaki packaging solutions 38 Packaging within the circular economy 42 SP GROUP 45 Amcor’s LifeSpan® performance paper 46 New, more friendly crisps!

Reusable Packaging 47 PakTech 48 A returnable supply chain

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9 Issue 1 Sep 2020

CONTENTS

30 20 45

14

48 Issue 1 Sep 2020

23 18 SUSTAINABLE PACKAGING NEWS

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SUPPLY-CHAIN SLEUTHS

Supply-chain Sleuths

Revolutionary

vision-based technologies Vimaan, a computer vision company for warehouse inventory management, has emerged from stealth to announce its solutions to the warehousing and logistics industry, along with $25 million in seed and Series A financing from top investors New Enterprise Associates (NEA), Wing VC and Neotribe Ventures.

6 SUSTAINABLE PACKAGING NEWS

SUPPLY-CHAIN SLEUTHS

Headquartered in Silicon Valley, Vimaan states its solution automates and digitizes inventory capture, tracking and management across the warehouse, including receiving, put-away and picking, storage and pack and ship.

“The process of collecting inventory data is a major bottleneck within warehouse management. While there have been some technological advancements in robotics and warehouse automation over the past decade, the Vimaan platform is the first of its kind to offer wall to wall coverage of warehouse inventory,” stated S. K. (“KG”) Ganapathi, Founder and CEO of Vimaan.

The solution is simultaneously capable of barcode and RFID reading. The data is presented to the customer in a software application that directly interfaces with the customer’s WMS and provides actionable insights.

“Warehouse managers constantly face competing objectives of keeping inventory tracking labor costs low while simultaneously keeping inventory accuracy high. Vimaan has worked hand in hand with our blue-chip customers to design solutions that strike at the heart of data tracking challenges in the warehouse. The Vimaan platform enables a warehouse manager to realize 100% inventory accuracy and visibility with minimal labour oversight. This in turn results not only in labour savings, but also in reduced inventory wastage, fewer claims and chargebacks, reduced reverse logistics costs and overall improvement in quality.”

“ benefits in productivity and cost savings ”

Multi-faceted capabilities The Vimaan platform comprises computer vision-based technologies—including cameras, a sensor suite and computer vision algorithms—to “see”, interpret, and digitally reconstruct inventory according to the warehouse’s requirements, the company explained.

For the past 24 months, Vimaan has been working with leading 3PLs and brand owners to perfect its inventory tracking solutions, the company added. These customers, who are in full production with Vimaan solutions, have realised significant benefits in productivity and cost savings, according to Vimaan.

“Inefficiencies within the warehouse and logistics industries have spotlighted huge opportunities for technological advancement and investment,” said Greg Papadopoulos, Ph.D., Venture Partner at NEA. “We’ve been enthusiastically tracking the warehouse robotics and automation industry for a while and are thrilled to expand our portfolio in the space by partnering with Vimaan to apply revolutionary computer vision technology to transform inventory processes and empower warehouse managers across the industry.”

This latest development appears to put other advanced warehousing systems in the shade and could well represent the future for warehousing management. There are many new and exciting developments in this field and Vimaan is certainly in pole position here, with one of the most futuristic offerings to date!

SUSTAINABLE PACKAGING NEWS

7

SUPPLY-CHAIN SLEUTHS

Sustainability integration - a comment from REPL

As we’ve explored in previous articles, the concept of sustainability is far broader and multifaceted than simply the environmental element, spanning instead the ‘five capitals’ of natural, human, social, manufactured and financial capital. By understanding this, sustainability leaders will be able to define the sphere of influence for their organisation to bring about positive change, making use of an array of tools, including data science.

Armed with this new sustainability mindset – and the right technologies – leadership teams can start to make a tangible difference across the business, including one of the most significant elements for any retailer or manufacturer: the supply chain.

The vastness of the supply chain is one of the reasons that there is such a wealth of associated sustainability benefits, with each mappable to both the United Nations Sustainability Development Goals, and those same ‘five capitals.’

By improving both stock management and decisions around sourcing, businesses can benefit from lower logistics and waste disposal costs. Equally, by improving the transparency of their own progress on sustainability, such as via reporting, they can demonstrably improve both employee and consumer engagement, with a knock-on impact on revenues.

8 SUSTAINABLE PACKAGING NEWS

Tesco, for instance, has been lauded for its decision to routinely reveal data on its levels of food waste.

“ There are so many opportunities within the supply chain to unlock sustainability ” Making a difference - at every stage There are so many opportunities within the supply chain to unlock sustainability, across each of the ‘five capitals.’ Simply put, the right technology can help a retailer not only reduce waste and emissions throughout their operations, but also improvement in both internal and external engagement, building better relationships with employees, suppliers, consumers and also their local communities.

RETAIL ROUND-UP

Retail Round-up

Ukraine support package Asda and the Asda Foundation to provide £1m support package for Ukrainian families and remove Russian products from sale.

Asda and its charity, the Asda Foundation, have today announced a £1m package to support displaced Ukrainian families in Europe and the UK.The supermarket is providing immediate support for families forced to leave their homes in the aftermath of the Russian invasion and long-term support for Ukrainian refugees that arrive in the UK. The support package includes the following measures: •

Pledging £100k in Asda Foundation support to national UK-based refugee support groups.

•

Making Asda Foundation grants of up to £580k available to support local and grass-roots refugee groups across the UK.

•

A £250k corporate donation to UNICEF to support the setup of a Blue Dot centre, providing a safe space for up to 5,000 children and families on the move and emergency water and hygiene kits to be deployed on the ground.

•

Essential supplies including George clothing, nappies, toiletries, period products and food delivered by Asda logistics partners to a supplier site in Poland for onward distribution in Ukraine.

John Cookman, deputy chair at the Asda Foundation said: “We have a long history of supporting grassroots community groups across the UK, and that includes when communities respond in times of global crisis.

As we look ahead to the coming months we see an ongoing need to support refugees arriving in the UK and are pleased to be able to play our part in helping groups to provide essential support services on the ground.”

Everyone at SPN fully endorses this action and hopefully many others in the FMCG business will follow suite with their own contributions.. Well done ASDA!

In addition to the support package, Asda will enable customer cash donations in-store and via grocery home shopping to international charities working on the ground in Ukraine and neighbouring countries. The supermarket has also confirmed that it is removing products that originate from Russia from its stores and online.

Mohsin Issa, Asda’s co-owner, said: “We stand with our customers and colleagues who are shocked by the Russian invasion of Ukraine – and our thoughts are with those people whose lives are affected by this crisis. The community spirit that is at the heart of Asda extends beyond our own borders and we’re proud to have worked with a range of partners in the UK to provide practical and meaningful support for Ukrainians at home and for those who continue to seek safety in neighbouring countries.”

SUSTAINABLE PACKAGING NEWS

9

Retail Round-up

Fashion for the better

It is two years since Fashion for Good published its special report, “Polybags in the fashion industry: evaluating the options”. Since then, as in many other industries, there has been a continued focus on the reduction of plastics in packaging, particularly single use. This has been driven by high-profile global campaigns such as those highlighting the damage being done to our oceans and their wildlife, and an overall awareness of the need to protect our planet, thanks to the focus on climate change.

This comment piece was created by Fashion-for-Good.

A global platform for sustainable fashion innovation. Its mission is to bring together the entire ecosystem to make fashion a force-for-good worldwide.

“Our own new research with UK consumers reveals the majority (87%) consider the recyclability of the packaging of fashion items such as clothes, sunglasses and accessories bought online or by mail order is important when making their purchasing decision. Over half (52%) said that poor packaging recyclability puts them off buying items online or by mail order altogether. We also know that consumers have genuine concerns about the environmental harm caused by plastic, 58% of consumers said it is plastic breaking down to microplastics in the ocean and harming wildlife which concerned them most. This was followed by plastics going to landfill (24%) and being incinerated and causing more pollution (12%). All points echoed in the Fashion for Good report.

Yet, despite increasing pressure for alternative packaging solutions as part of a green revolution, progress is slow, with the majority of garment and accessory bags still made from Low Density Polyethylene (LPDE), and billions used every year. Of course, fashion products need to be protected on their journey to the consumer to ensure they arrive in perfect condition, so packaging is a necessity. It must protect from moisture, be strong and puncture resistant, heat sealable and also be suitable for labels and bar codes. However, should these functional attributes be at the expense of the end-of-life of the packaging?”

“ despite increasing pressure for alternative packaging solutions as part of a green revolution, progress is slow ” 10 SUSTAINABLE PACKAGING NEWS

“The reality is that there are a range of packaging alternatives available which offer more favourable end-of-life options in terms of recycling and biodegradability, albeit none are yet the silver bullet the industry seeks and there are challenges to overcome before they are adopted widely. However, they are a significant improvement on LPDE and far less harmful to the environment.

RETAIL ROUND-UP

Brands need to be aware that packaging innovation has delivered solutions which are now readily available, including starch based compostables and new-generation plastics such as Hydropol, which is based on PVA, and offers all of the functionality of LDPE, but are fully recyclable and biodegradable without producing harmful microplastics, which are so damaging to the environment. So, if these products offer all of the product protection provided by traditional plastic packaging without the negative environmental impact, why aren’t they being widely adopted?

The answer is chicken and egg. Although materials made with Hydropol are fully recyclable – indeed, in combination with paper, it actually enhances the recovery of paper fibres in the recycling process - we still have to work with the existing recycling infrastructure which has yet to fully adjust to the circular economy.

The more brands collaborate and adopt new packaging technologies such as Hydropol, increasing the volume of PVA material, so will the viability of recycling around the world, closing the loop and making the circular economy a reality.

“ Brands need to be aware that packaging innovation has delivered solutions which are now readily available, including starch based compostables and new-generation plastics ” The paper recycling stream is an existing and generally available route to economic, technical and viable end of life which the consumer understands and, in many cases, has access to the collection stream. We also need to ensure consumers are educated about the benefits and attributes of choosing alternative packaging. They need more choice in terms of how they can dispose of their packaging, whether it is through the recycling system, dissolving it in the dishwasher or washing up water, or compositing it”.

“There is a huge opportunity for fashion industry brands, which can make a positive impact right now by switching to the alternative packaging solutions which are already available – the more that do, the quicker the pace of change. For good.”

Sainsbury’s and Argos celebrate new milestone Sainsbury’s has today reached a significant stage in its plans to bring Sainsbury’s and Argos closer together with the opening of its 400th Argos store inside a Sainsbury’s supermarket.

The launch of the new Argos in Sainsbury’s Crystal Peaks in Sheffield follows the opening of two similar stores in stores in Belfast and Waltham Cross earlier this week. By offering more customers the chance to shop the much-loved brands of Sainsbury’s, Argos, Habitat and Tu Clothing under one roof, the retailer is delivering its plans to make shopping more convenient for customers.

More than half of all Argos stores are now located within Sainsbury’s supermarkets, making it easier for customers to browse and collect tens of thousands of affordable technology, home and toy products whilst picking up their groceries. Argos is a technology-led business – its website is the third most visited of any UK retailer and 90% of Argos sales now originate online. The new stores in Sainsbury’s stores allow customers to benefit from Argos’s market leading Fast Track delivery and collection service, giving them the option to order products for same day collection from store in as little as four hours. Customers can also use tablets in the digital Pay@Browse area, enabling them to choose and purchase what they want quickly and conveniently instore.

Patrick Dunne, Sainsbury’s Property Director, said: “This is a fantastic milestone for us that shows how we’re continuing to invest in our estate to improve the availability of great value Argos products for customers. It’s amazing to see how far we’ve come from the opening of our first Argos store inside a Sainsbury’s in 2015 and we know our customers have enjoyed the added flexibility and convenience offered by these stores ever since.”

“ we’re continuing to invest in our estate to improve the availability of great value Argos products for customers ” In the highly competitive marketplace of the supermarket giants, it is Interesting to note that Sainsbury’s continues to look outside the box in order to add to its customer base and growing consumer appeal. SPN believes that the prospect for consumers to be able to shop for Argos, Habitat and TU at Sainsbury’s will be an attractive proposition for many.

SUSTAINABLE PACKAGING NEWS

11

SPONSORED

CHEMUK 2022 Presents ‘The Chemical Industries Supply Chain Show’ • • • • • • • •

Chemicals, Raw Materials & Ingredients Chemical Logistics & Transportation HSE Management & Regulatory Compliance Specialist Chemical Labelling Toll / Contract / Outsourcing/ White & Private Label Services R&D/Laboratory, Analytical & Testing Skills, Training & Recruitment Business & Operational Support

Expanded Sustainability & Circular Economy agenda at CHEMUK 2022: New for 2022 is the dedicated ‘Sustainability Stage’, hosting panel sessions and feature presentations embracing critical themes such as chemical recycling & sustainable chemical processing, together with ‘green chemistry’ innovation and transition to bio-based products.

The CHEMUK 2022 EXPO returns on the 11th & 12th May 2022 at the NEC in Birmingham. The event will showcase 300+ specialist exhibitors and 100+ expert speakers across two co-locating shows; ‘The Chemical Industries Supply Chain Show’ and ‘The Chemical, Process & Plant Engineering Show’.

The Chemical Industries Supply Chain Show The Chemical Industries Supply Chain Show will showcase specialist exhibitors to attending Product Development, R&D, Supply Chain, Operational and Logistics teams from across the chemicals, chemical products & chemicals-dependent industries, covering:

Also new for 2022 will be the ‘Bio-Based Chemicals & Processing INNOVATION ZONE’, showcasing breaking innovation start-ups, university spinouts etc, with exciting concepts.

Dates For The Diary CHEMUK 2022 takes place on Wed 11th & Thu 12th May 2022 Venue: NEC - National Exhibition Centre, Birmingham, B40 1NT

Opening Times: Day 1: 9.30am – 5.00pm | Day 2: 9.30am – 4.00pm Register for your FREE entry badge at www.chemicalukexpo.com

SPN Circular Economy Conference The SPN Circular Economy conference is now available to watch online, featuring a variety of world-class speakers.

Some of these speakers include: Tom Szaky the CEO of TerraCycle, Nerida Kelton – Executive Director of AIP (Australian Institute of Packaging), Shira Rosen – Chairman of the Israeli Packaging Institute and Valentin Fournel – Director R&D and Services Eco-conception at CITEO. All these speakers have one thing in common, wanting to change the way we recycle our packaging so we can make the world we live in more sustainable. We know that by promoting Circular Economy, we will be able to educate and show people how we can better our efforts in recycling, reusing, and reducing the amount of packaging we use.

Visit : www.spnews.com/circular-economy-conference/

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RESOURCE EFFICIENCY

Delivering resource-efficient design and packaging Moelven material use is optimised and waste quantities reduced through resource efficient design and industrialised production in controlled environments in the factory, on the construction site and during the usage phase.

Moelven is aware that it impacts the environment both through its own industrial operations and the use of our products. However, its material use is optimised and waste quantities reduced through resource-efficient design and industrialised production in controlled environments in the factory, on the construction site and during the usage phase.

For practical reasons, many products must be stored and transported exposed to the elements. The correct packaging is important in order to preserve quality, although this often also presents environmental challenges. Moelven uses a lot of plastic for packaging.

Sustainability Starts Here: •

The utilisation of raw materials must be optimised to improve resource efficiency and to maximise the value of the raw materials.

•

Products must be designed with a focus on resource efficiency. Unnecessary packaging must be minimised.

•

The use of plastic must be minimised. Alternative materials to plastic must be actively sought.

Moelven currently uses a polythene film made from 95 per cent recycled plastic as cover packaging. At the same time, work is being done to find alternative and even more sustainable solutions. There are working products on the market that are made from reinforced paper laminated with a layer of polyethylene and polypropylene. However, the products are costly and difficult to recycle due to their complex composition.

Trials are taking place at Moelven Valåsen AB involving PE laminated liquid carton, where the sides are treated with wax as simple protection against humidity. The PE laminated liquid carton is recyclable when fibre is separated from the PE component. The trials are promising, but much development remains before this solution can replace current plastic packaging based on recycled plastic.

At its own facilities, Moelven can make sure that a waste management system is in place that ensures the highest possible degree of recycling and reuse. On the other hand, Moelven’s is largely unable to influence what happens to the packaging used for its products that are distributed in the market. It is therefore important to make sure that as little packaging is used as possible and that it is as environmentally-friendly as possible.

The work on surveying plastic consumption to identify opportunities for reducing it and at the same time and cut costs is a high priority. The products developed in the timber processing industry must in most cases be packed in some sort of protection against the elements. As a rule, direct deliveries straight from the manufacturer to the customer with no intermediate storage where the products may be exposed to precipitation, dirt or sunlight are not possible. In order to preserve quality and thus value, packaging is used that meets specific requirements for waterproofing, UV protection and tearing strength.

SUSTAINABLE PACKAGING NEWS

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RESOURCE EFFICIENCY

GEW

UV systems? GEW has a cure for it

GEW UV curing systems represent the future for packaging companies in a world where evolving innovative packaging is designed to protect, preserve, and dispense products.

The same packaging must also make products easier to handle, transport, store, and use. In addition, integrated counterfeit protection devices are also able to ensure the authenticity of goods, and today’s built-in traceability, facilitates easier product recalls.

Currently, packaging converters and consumer packaged goods (CPG) companies rely on a mix of UV printing and UV coating technologies, in order to deliver aesthetically pleasing designs. These can feature bold colours; tactile, haptic, and special effects; as well as glossy and matte varnishes that promote and protect the package’s internal contents. In addition, they may develop innovative functionality tailored to specific markets and preferred portion sizes, thus differentiating products, and facilitating improved sustainability. Examples of UV curable application technologies utilised by both rigid and flexible packaging converters include gravure, flexo, offset, digital inkjet and screen, all of which can be equipped with GEW’s mercury arc, UV LED, and hybrid lamp designs.

“ companies rely on a mix of UV printing and UV coating technologies, in order to deliver aesthetically pleasing designs ”

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Hybrid Arc & UV LED curing systems offer package converters a wide variety of printing options Mercury vapour UV curing technology has been established in various segments of the packaging industry for over half a century. By comparison, UV LED curing is a relatively new technology that is only used minimally in rigid and flexible packaging. For those new to LED and not fully convinced of the technology’s capabilities, Arc/LED hybrid solutions, which consist of a cassette style lamphead and universal power supply, allow printers and decorators to swap between LED and mercury cassettes quickly and easily. This means packaging converters can easily experiment on press by its qualifying processes, and transition to UV LED at a pace that suits their need and comfort.

GEW’s ArcLED concept employs this hybrid UV curing technology, thus allowing interchangeability between conventional UV arc or LED on the same print unit.

RESOURCE EFFICIENCY

This can simply be done by changing the cassette. Both arc and LED cassettes are compatible with GEW’s RHINO power supply unit (PSU) and fit in the same lamphead housing.

The entire process is operator-controlled using an intuitive Human Machine Interface (HMI) touchscreen. The HMI operates up to 16 lamps simultaneously and is customised

by GEW for each unique machine configuration.

All new GEW UV systems are powered with rectifying power supply units (PSUs) designed to provide mercury vapour lamps with AC power and LEDs with DC power. These are available in a range of sizes of up to 27kW.RHINO’s advanced, high-level specification and safe shutdown capability also protects the system from a long list of common electrical issues and is proven to run for many years in the harshest of environments. Intelligent power management, balances mains draw and minimises harmonic distortion, leading to reduced energy demand.

All internet connected RHINO-powered systems are regularly monitored by GEW service engineers. Remote Monitoring enables encrypted system performance data to be pushed to the cloud where it is accessed by GEW, ensuring the fastest and most precise service response available. A preventative maintenance program recommends software and hardware updates, and highlights and corrects out-of-tolerance parameters before any issues arise in production, often allowing GEW to fix problems without attending a production site. Importantly, this also keeps the carbon footprint low for package converters. Comprehensive monthly system performance reports are automatically generated and emailed to users, so press productivity can be monitored more closely than ever before.

UV LED systems taking centre stage Industries that are leading the adoption of LED curing include those using UV digital inkjet and flexo technologies.

With LED inks and coatings far more widely available and cost-effective today, the landscape is shifting more rapidly in this direction. Additionally, many formulators now supply dual cure chemistries that polymerise when exposed to either LED or mercury vapour. This encourages adoption as it reduces the number of SKUs that must be produced and carried in inventory.

The combined use of LED across digital inkjet, narrowweb, flexo, and commercial sheetfed offset now represents around 25% of GEW’s production, and this figure is steadily rising. Packaging manufacturers are following these early market leaders and are now considering LED technology for their own, more demanding processes. This is because the longer wavelength LEDs penetrate polymer films better than conventional UV, making LED the ‘go-to’ for cast and cure, and cold foil adhesives.

GEW’s latest water-cooled LED innovation, LeoLED, has had a significant impact on the packaging market since its launch in late 2019. LeoLED has been redesigned and refined for simplicity and offers excellent value, whilst at the same time delivering maximum power and dose of UV energy.

The LeoLED cassette is fully compatible with GEW’s ArcLED hybrid system and brings UV LED within affordable reach for all package converters. Economies of scale are soon realised since the same core LeoLED technology is suitable for container decorators requiring one or more lamps as short as 15cm, through to wide-web applications requiring one or more lamps as long as 170cm.

For high-speed web and sheetfed offset applications within the packaging sector, the lower profile LeoLED Standard offers all the same benefits and specs as the LeoLED cassette. It is also easily configured in a Modular Lamp Array (MLA) that is a customisable arrangement of LED mounting positions integrated at the end of a printing press or coating line.

Lamps can be freely moved between any position to change curing configuration and adapt to the job at hand, for highly demanding applications, multiple lamps are placed-in series.

SUSTAINABLE PACKAGING NEWS

15

Recycling V biodegradation

Oceans of plastic

Confusion often reigns when it comes to the disposal of certain polymers.

Companies must make the choice between Recycling or Bio-degradation.

SPN therefore asked Samir Jabir, a leading polymers expert and technical writer at the Sustainable Materials Database Company ‘Matmatch’, which plastics can be recycled, and which are most suitable for biodegradation?

“Plastic pollution has recently returned to the forefront of public discourse following last November’s COP26 summit, where Bermuda’s deputy leader called for “aggressive action” to tackle the problem. Although many manufacturers have taken steps to clarify the end-of-life treatment of plastics, there is often still some confusion about how best to dispose of certain polymers. Here, Samir Jaber, technical writer at sustainable materials database Matmatch, examines recycling and biodegradation of polymers - and how both fit into sustainable practices.

“ Several million tonnes of plastic waste enter the environment each year ” Several million tonnes of plastic waste enter the environment each year, whether as discarded litter, landfill or marine pollution. It was the latter that drew the ire of Walter Roban, deputy premier of Bermuda, during COP26, stating: “plastics thrown as waste in large countries like the United States and others are getting into the ocean and then finding themselves on our shores”.Roban added a call for action on single-use plastic waste from developed nations: “We hope the US and other large countries aggressively address the issue of disposal of single-use plastics to solve what is a global ocean problem that we see every day in Bermuda.”

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Of course, there is no simple solution — aggressive or otherwise — to a problem as complex as plastic pollution.

As far as single-use plastics are concerned, one debate that has waged in the industry for several years is whether recycling or biodegradation is a better end-of-life solution.

Recycling Recycling a waste plastic product to reuse the material in a new application has a multitude of benefits, both environmentally and economically. However, the main limitation is that of infrastructure; not every recycling facility is equipped to handle every type of plastics, nor can every city, region or country access specialised recycling resources.

This limitation is reflected in the resin identification codes on products themselves, which indicate the level of difficulty to recycle each plastic. Polymers with a resin identification number of three or above are harder to recycle and, due to this, are not universally accepted at recycling centres. This affects polymers such as polypropylene (PP), which has the identification number five. Recycling PP involves an intensive five-step process, which adds to the difficulty for recycling facilities and contributes to the material’s lower recycling rate — less than one per cent in post-consumer plastics.

Recycling V biodegradation

Biodegradation Conversely, biodegradation is often maligned due to a lack of biodegradation standards for various environments, a misunderstanding of what constitutes biodegradation and a perceived risk of negative behavioural consequences — that is, concerns that biodegradable plastic products may encourage consumers to dispose of more goods in the environment. One of the most significant factors that have affected the perception of biodegradable polymers is a lack of regulatory enforcement of standards for all environments.

This allows some product designers to conflate plastics that are biodegradable with those that simply degrade in natural environmental conditions.

Classifying a polymer as biodegradable must involve adherence to a set definition; one in which all the components of a plastic are aerobically or anaerobically converted into environmentally benign resources, such as carbon dioxide, mineral salts and biomass. This means that oxo-fragmentable plastics that break down into microplastic fragments, many of which do not fully degrade into organic matter and instead accumulate in the environment, would not be mistaken for a biodegradable material.

Striking a balance However, there is no single end-of-life solution for plastics.

Whether a product is best suited to biodegradation or recycling depends predominately on the application. This was among the focuses of the BioSinn project by experts from the nova-Institute in Hürth, Germany, which sought to identify applications or products that benefit most from biodegradation. In mid-2021, the project published a report of its findings, which outlined areas where biodegradable polymers are advantageous and suggested several polymers that are best suited. This report also gave an in-depth exploration of the behaviours of biodegradable polymers in different environments, which affects the timeframe for degradation and influences a product designer’s selection.

Unsurprisingly, many of the ideal applications for biodegradable polymers are those that are single-use in nature, such as labels, small packaging and packing materials - or that are prone to fragmentation during use, such as dolly ropes on fish trawlers

Agricultural markets highlight the challenge The agricultural market is one that is highlighted in the BioSinn report, with a number of applications that will benefit from the greater use of biodegradable polymers, such as coatings applied to seeds to enhance germination.

These coatings can contain any number of active ingredients to protect the seed, but they usually feature a polymer binder to provide adequate adhesion to the seed and extend the lifespan of the active ingredient. Often, these polymers are polyvinyl alcohol (PVA) or polyvinyl acetate (PVAC) due to both polymers’ high adhesive strength to porous substrates, water resistance and ductility.

However, the coatings often contain synthetic compounds that do not degrade in soil. There are alternatives based on biological polymers, such as chitosan or cellulose, but these are yet to receive significant market support. BioSinn also notes that there is not yet an alternative polymer that has been certified for biodegradation in soil - something that materials scientists are working to address. Materials such as polylactic acid (PLA) may be a potential option due to its ability to biodegrade in soil over a long period of time.

However, this material doesn’t yet degrade fast enough to meet the requirements of standards such as TÜV Austria or DIN CERTCO. This presents one of the challenges for any material substitution: ensuring that the material matches not only the mechanical or thermal properties but also the certification potential.

“ The agricultural market in particular boasts multiple other applications that highlight the challenge ” The agricultural market in particular boasts multiple other applications that highlight the challenge. Tree shelters, for example, are often left in forested areas as the trees outgrow them, with BioSinn extrapolating that this application accounts for approximately 20,000 tonnes of plastic use in the European Union each year.

Despite the high volume, very few tree shelters currently degrade due to being fabricated from high-density polyethylene (HDPE) or rigid polyvinyl chloride (PVC).

These materials are seen as necessary to withstand the outdoor environmental conditions for at least five years as per regulatory guidelines while also having a suitable elastic modulus for the structure to stretch as the tree grows.

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Bottles V Cartons

Elopak

Packaging chestnut The old packaging chestnut about the sustainability virtues of plastic bottles versus cartons is still a difficult one for some, as Elopak’s Chief marketing Officer explains: “For years beverage producers have agonised over a seemingly simple decision: bottles or cartons? This apparently straightforward question has serious consequences for how brands present themselves on the shelves and communicate their commitment to sustainability”.

While both plastic bottles and paperboard cartons are widely recycled, recent research shows substantial environmental benefits for companies choosing to use cartons. An independent Life Cycle Assessment carried out by the University of Southampton comparing different types of packaging for milk and fruit juice found that beverage cartons had a significantly lower impact on the environment than either glass or plastic bottles.

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Bottles V Cartons

At Elopak, we have long believed that beverage cartons offer a natural and convenient alternative to plastic bottles which fit within a low carbon, circular economy. Now, more brands than ever are waking up to this fact.

In October 2021, Scottish family dairy Graham’s switched from plastic bottles to cartons; packaging its line of organic milk in 500ml Pure-Pak® cartons made with Natural Brown Board.

The decision followed extensive customer research, which showed that 76% of consumers choose their food and drink based on sustainability. 59% of respondents also said that reducing plastic waste was important.

Faced with these facts, Graham’s Managing Director Robert Graham said “It was clear that any change in packaging must present no compromise on freshness and quality – delivering the same fresh milk in a better package for the environment.”

He therefore opted for Pure-Pak® cartons, citing that they are made from renewable forest-based materials which are responsibly sourced and manufactured using 100% renewable electricity.

In a similar vein, Morrisons – the U.K.’s fourth largest supermarket – also recently switched from bottles to cartons for its line of own-brand fruit juice. In November 2021, the retail giant opted for 1l Pure-Pak® Sense cartons which it nicknamed ‘our clever cartons’. On the side of the packaging, the supermarket described the switch as a “more sustainable option, with a lower carbon footprint”.

By placing sustainability at the forefront of its packaging choices, Morrisons demonstrated a similar awareness of consumers’ environmental concerns. Additionally, by choosing Pure-Pak® Sense cartons with easy-folding lines, it helps customers to more easily recycle their packaging once they’ve finished enjoying the product.

As more brands makes the switch from bottles to cartons, it seems as though sustainability may be the final word in this debate. At Elopak, we look forward to helping brands accelerate this transition and enabling more customers to make environmentally conscious choices.

All comments attributable to Elopak Chief Marketing Officer Patrick Verhelst.

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Corrugated Packaging

Corrugated sector seeing consistent growth DS Smith continues to lead the field as it strips out more than 170 million pieces of problem plastic for industry, supermarkets, and online retailers. In addition, it is set to replace more than one billion pieces of single use plastic by 2025.

DS Smith has announced strong progress towards its plastic replacement targets as part of its Half Year Financial update to the market. The company reported 170 million pieces of problem plastic had been replaced by its paper-based solutions for supermarkets and online retailers around the world since the launch of its “Now and Next Sustainability strategy” last year.

The leading sustainable packaging business has removed on average more than 2 million pieces of single use plastic a week from its customers packaging and store display products – equivalent to 12,000 pieces an hour – boosting their customers’ packaging recyclability and reducing the impact on the environment.

“ We are working with our customers to replace more than one billion pieces of problem plastic ” “We are working with our customers to replace more than one billion pieces of problem plastic with fully recyclable, fibre-based packaging solutions by 2025. Consumers are increasingly demanding less waste from their products, and we are embracing this agenda for change to protect the planet and create a more sustainable future, said Miles Roberts, Group Chief Executive at DS Smith.

With businesses across the EU paying a new plastic packaging tax which is set to raise up to €8bn a year in revenue, DS Smith has created more than 1000 wholly recyclable fibre-based packaging solutions for hundreds of thousands of products for both traditional and e-commerce retailers – covering everything from wine boxes and readymeal trays to shrink wrap and fresh fruit punnets.

Using its industry leading Circular Design Principles, DS Smith has engineered a raft of innovative designs to eliminate even the smallest amounts of plastic packaging - replacing plastic sealing tape with self-locking cardboard flaps and swapping plastic labels with print direct onto cardboard.

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Corrugated Packaging Linerboard production

Corrugated market segments The corrugated slotted boxes segment leads the market in terms of both value and volume. They are generally made from one piece of corrugated board which is usually stitched, taped, or glued. The blank, or tray, is scored and fitted to allow folding after which the boxes are dispatched flat to the user. To make a box, the user needs to square it up, place the product in the box, and shut the flaps. The flute is placed parallel to the depth to provide enough loading strength.

The slotted box is a very efficiently designed product, as it generates minimal waste during its manufacturing process.

Linerboard remains the largest material segment The linerboard material segment led the market in terms of both value and volume. Kraft liner contains at least 80% virgin kraft pulp fibres. Due to its high strength and moisture resistance, kraft liner is used as an outer and intermediate ply in corrugated boxes. The kraft linerboard is primarily used for the manufacture of high-grade colour-printed corrugated boxes for the food & beverages, home & personal care, and other industries. Recycled linerboard, also known as a test liner, contains less than 80% virgin kraft pulp fibres. It is also used for the outer and intermediate plies of corrugated board. However, it is not as strong as kraft liner as it has a higher recycled fibre content. Recycled linerboard is less expensive than kraft liner. The recycled materials used for manufacturing recycled board include double line kraft clippings and old corrugated containers.

Water-based ink the largest ink segment The water-based ink segment led the printing ink segment of the market by both value and volume. Water-based inks are composed of pigments or dyes in a colloidal suspension with water-soluble resins or resin emulsions. Typically, waterbased inks contain a higher percentage of solids, which implies that there is less liquid to be removed. Owing to the nature of resins present in the water system, a thinner layer of ink is often used. Water-based inks are available in two varieties: dye and pigment. Although dye inks result in highquality images, they are not waterproof and fade if exposed to UV light. Pigment inks are short-term waterproof inks with high stability in UV light.

Flexography printing Flexography segment leads the printing technology of the market. Flexography is a quick and economical printing technique which is widely used in packaging printing due to the wide range of benefits offered. It is used to apply simple designs and colours to a wide range of packaging materials, such as corrugated boxes, plastic containers, tapes, envelopes, and metal foils. Flexography printing technology has the highest demand for printing on corrugated boxes.

It is a form of relief printing which uses rubber or polymer plates to transmit an image onto a corrugated board such as in an automated rubber stamp. Flexography printing was invented in order to print on rough and uneven surfaces such as corrugated boards. The printing ink used in flexography printing is fast drying and of low viscosity. It is therefore considered to be a quick printing method. As corrugated boards are highly porous, flexography printing is ideal for plain text or 1-2 colour graphical images.

Corrugated packaging’s ability to meet many practical and sustainability challenges has seen its popularity grow yearon-year. SPN is hopeful that this consistent growth will continue as its flexibility and sustainability credentials are appreciated by Packaging companies both large and small across the globe.

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PRINTING INKS

Sirane Group

Life enhancing solutions The Sirane Group has set up a new flexible packaging facility In the US, soley dedicated to the devlopment and manufacture of environmentally friendly, water based Inks, coatings and adhesives. Sirane says that its smart solutions are already life-enhancing.

Sirane’s Marketing Manager, Mark Lingard told SPN, “Our Technical and NPD Teams have worked tirelessly to get the right formulations for the inks and coatings. The demands were high as we needed the technology to work on both papers, recyclable plastic and plastic substrates that contain PCR content. Sirane invested money and time in order to ensure that the technology is right.

Traditionally within the packaging industry, Solvent Based Inks would have been used during the manufacturing of this product. When the solvents are being dried volatile organic compounds (VOC)’s are released into the atmosphere, which need to be dealt with. This often involves burning more gas.

Therefore, we use water as a carrier for the pigment instead of these solvents. So much better for the environment!

Sticking to sustainability Lingard added, “The typical adhesives used in the packaging industry contain aromatic isocyanates which release aromatic amines, these include compounds classified as potential human carcinogens and known to cause cancer in animals. To conform to current legislation, laminates must cure in a warm environment to reduce the amount of these harmful substances that can migrate into the product.

“Other unwanted substances found in packaging adhesives are: Bisphenol A Diglycidyl Ether (BADGE), Bisphenol F Diglycidyl Ether (BFDGE), or Novolac Glycidyl Ether (NOGE).

None of our our water-based adhesives contain these harmful ingredients that can migrate into the product!

The same dediction to safety and the environment are also present in our advance coatings.

“Sirane has always been about innovation and packaging development. We keep pushing the boundries of sustainable packaging. It has been great that the team has been given the time and resources to create this fantastic facility and expand our range of sustainable packaging”, said Peter Ralten, Head of Specialist Packaging at Sirane.

Ralton continued, “Sirane is an innovative packaging development-to-manufacture company, with expertise in absorbency and material science. The company’s specialisms include: board; bags, pouches & film; absorbent products; shelf-life extension; plastic replacement and dualovenable products.

The group has four main divisions: food packaging; horticultural; medical & healthcare; and lab supplies & services. The company is based in Telford, UK, with additional manufacturing in Guadalajara (Mexico), Hranice (Czech Republic) and Moscow (Russia), with a network of agents and selected distributors.

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PRINTING INKS

Pulse-roll Label products extend its range Pulse Roll Label Products has launched a new product innovation called PureFX Soft Touch Varnish, thus extending its special effects range to offer a unique UV tactile coating sensation.

Demand for tactile finishes is increasing with brand owners seeking haptic coatings that add a premium touch and feel to a consumer package or label. However, achieving a UV soft touch effect has historically presented challenges for narrow web printers due to the nature of UV free radical curing.

With this new development, Pulse Roll Label Products has formulated a product to overcome this and offer an alternative for companies choosing to move away from film or water-based coatings. Testing of the new PureFX Soft Touch Varnish took place at selected label printing sites and yielded results that provided a soft touch effect the company believes is comparable to soft touch lamination films and water-based flexo.

Demonstrating excellent adhesion, overprintability, press stability, and chemical resistance properties, the PureFX Soft Touch Varnish is suitable for a range of substrates including coated PE and PP, aluminium foils and paper. The product is also food packaging compliant, formulated for non-direct food contact packaging applications, and is particularly well-suited for end-use markets including, but not limited to, cosmetics, beauty, personal care, baby care and beverages. As well as conventional UV flexo printing, the new varnish is also suitable for finishing over digital inks to create a soft, smooth effect.

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PRINTING INKS

Domino

Inks for food packaging - the Domino effect

Sourcing inks for food packaging? Domino is shedding new light on an ever-changing consumer and regulatory landscape. Here Josie Harries of Domino Printing Sciences looks at the challenges facing manufacturers when sourcing inks and provides some vital insight into what brands can do to ensure that the inks used in their coding and marking applications, remain compliant with current and future regulations

Substances and chemicals used in the design and manufacture of food and beverage packaging have attracted significant global attention in the last few years - with consumers calling for increased transparency on the substances used on food contact materials. These substances include the inks used in the coding and marking and labelling of products and packaging. To protect consumer health and safety, food packaging inks are highly regulated and subject to an ever-changing regulatory landscape which can cause significant challenges for manufacturers.

The importance of inks for food packaging Product labelling, and coding and marking, are a crucial part of global food and beverage markets – allowing food and beverage manufacturers to communicate key information to consumers, as well as to logistics workers, retailers, and anyone involved in global food supply chains.

For consumers, this may include expiration dates, ingredients, allergens, and nutritional values, as well as information on how certain ingredients have been sourced - e.g. whether a product contains sustainable palm oil or fair-trade cocoa. From a wider supply chain perspective, batch, product, and traceability codes facilitate a product’s journey from manufacturer onto the supermarket shelf and are crucial in assisting with recalls on occasions when something goes wrong during production – e.g., in the event of undeclared allergens.

With the above in mind, it’s vital to ensure that any codes included on food packaging will withstand the journey that a food product makes, and last throughout a product’s shelf life.

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The type of ink used will vary from substrate to substrate – for example, a durable, high-contrast ink suitable for cardboard boxes will have different characteristics and composition from one that is suitable for printing on the film lids of yoghurt pots, where the risk of smudging requires an ink with quick-drying properties.

“ performance is not the only factor to bear in mind when developing inks for food packaging ” But performance is not the only factor to bear in mind when developing inks for food packaging. As well as being robust, reliable, and fit for purpose, any formulation must also be safe to use with food products, requiring assurances that inks will not compromise the integrity of, or migrate through, product packaging, or pose a threat to consumer health if the ink comes into direct contact with food.

PRINTING INKS

Spotlight on consumer safety Consumer health and safety is a top priority when developing inks for food contact packaging. Food and beverage manufacturers have a moral and legal obligation to ensure that any ink used on food packaging is safe for its intended use – and we are also witnessing a growth in consumer interest in, and knowledge of, the chemicals included within food packaging.

For example, the use of per- and polyfluoroalkyl substances (PFAs), so-called ‘forever chemicals’, which are typically used to coat food packaging and make it grease-and water-resistant have come under significant criticism recently, with many US states restricting their use. Growing consumer awareness is leading to increasing demand for transparency in how products and packaging are manufactured.

“ Growing consumer awareness is leading to increasing demand for transparency in how products and packaging are manufactured ” Food producers are, ultimately, legally responsible for any ink used on their product packaging – so working with proven and reputable ink suppliers, who are aligned with key industry associations and able to advise and assist manufacturers with ensuring compliance is key to providing this transparency and assuring that inks are safe for use on food packaging.

Regulations and guidance will vary depending on the countries in which products are sold.

The European Printing Ink Association (EuPIA), which counts Domino as an active member, has devised Good Manufacturing Practices (GMP) guidelines to help ink producers meet their obligations relating to articles that come into contact with food – including European Regulation (EC) No.1935/2004 and Regulation (EC) No. 2023/2006, and ISO9000 and ISO22000 standards. In the United States, similar advice is provided in guidelines relating to Current Good Manufacturing Practices (CGMPs), which are regulated by the US Food and Drug Administration.

Manufacturers are currently exploring alternative substrates and materials, including recycled cardboard and plastic, compostable materials, and refillable packaging. Each one has its own properties, and inks must be designed with these in mind.

Conclusion Product labelling, and coding and marking, are a small but vital part of global food and beverage supply chains.

Equally, the sensitive nature of food and beverage packaging means that inks used on food product packaging are highly regulated – and it’s up to brands to ensure that the inks used on their packaging are compliant.

“ Choosing the right supplier is key ” Choosing the right supplier is key – brands should look for a partner with a robust and proven understanding of the global regulatory framework, and the in-house capabilities necessary to remain abreast of industry trends and provide globally compliant solutions, whatever the future holds.

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Plastic Packaging

Flexing sustainability muscles UFlex, is a multinational flexible packaging company based in India that has launched a ground-breaking range of high-value-line products.

Ashok Chaturvedi, the company’s chairman and managing director, told SPN, “UFlex has been walking the green path by recycling post-consumer (PCR) multilayer mixed plastic waste, upcycling recycled resins into our PCR films range, and creating solutions that use less virgin plastic. A new highvalue-line of products and solutions are aimed at adoption of responsible packaging and mirrors our increased focus and investments in research and development.”

“ UFlex has been walking the green path ” Chaturvedi added, “We’ve tapped the company’s R&D outpouring in highlighting the six flex-pack breakthroughs in our slideshow gallery. These include easy-opening features for children, temperature-resistant spouted pouches for hot tea, high-barrier monolayer recyclable films, a new printing technique for woven packaging, and more”

Amcor CEO, Ron Delia, talks packaging trends on new McKinsey podcast The latest edition of the McKinsey on Consumer Retail podcast features Amcor’s CEO, Ron Delia, discussing the biggest trends in packaging.

Hosted by McKinsey’s Monica Toriello, Delia joins David Feber, the leader of McKinsey’s Packaging Service Line, in discussing “creating good packaging for packaged goods” and other areas both impacting and influencing the nearly trillion-dollar global industry.

The 25-minute podcast addresses the role packaging will play in the future, the importance of both industry and consumer education regarding sustainability, the influence growing market forces have on packaging, and innovations that are making packaging smarter for customers and consumers.

The McKinsey on Consumer Retail podcast, featuring Amcor CEO, Ron Delia, is available for download from Spotify, Apple and Google Podcasts.

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SUSTAINABLE PACKAGING NEWS marchesini.com

Plastic Packaging

UK government announces its largest ever investment in sustainable plastic packaging The Smart Sustainable Plastic Packaging (SSPP) Challenge has announced £30 million in funding for 18 ground breaking collaborative projects.

These projects support the achievement of the UK Plastics Pact and have the potential to alter the UK’s relationship with, and management of, plastic packaging.

The SSPP Challenge represents the largest government investment into sustainable plastic packaging and waste management to date, at around £30 million. The results of the two funding competitions just announced see five large scale demonstrator projects and 13 business-led research and development projects benefit from this backing.

Each has demonstrated its value in addressing the need to transform the UK’s retail and packaging supply chains and support the development of more sustainable approaches to plastic packaging use.

This is through a range of: •

circular economy business models

•

novel polymer materials

•

new recycling technologies.

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Large-scale demonstrator projects The successful large scale demonstrator projects are focused on three key packaging challenges: •

reuse and refill

•

food grade polypropylene recycling

•

films and flexible packaging recycling.

Refillable packaging project Unpackaged is leading a collaborative, cross-sector refillable packaging project including in-store and home delivery.

Involving real world trials of a circular supply chain solution to scale up refill for in-store and online retail. It brings together not only major supermarkets Morrisons and Waitrose but also home delivery retailer Ocado and logistics experts CHEP, part of Brambles Ltd.

“ the trial aims to tackle the challenge of single-use plastic packaging ” This highly ambitious and ground-breaking multi-retailer, multi-site demonstrator trial aims to tackle the challenge of single-use plastic packaging. This is by creating an innovative system for dispensing and refilling both liquid and dry products into consumers’ own reusable containers either in-store or at home.

Plastic Packaging

Return refill, repeat project Beauty Kitchen’s major return refill, repeat project will deliver a major trial of a pre-filled and returnable packaging scheme for liquid products in partnership with: •

RBC Group, experts in logistics and automated retail

•

environmental charity City to Sea.

SPN says that this latest investment by the UK government is a welcome contribution to the considerable on-going investments being made by packaging companies both large and small worldwide. It also sends a signal to other countries by encouraging them to follow the UK’s example and to make similar contributions towards a greener, more sustainable planet for mankind.

Building on learning from previous smaller trials, the aim is to create behavioural change among brands, retailers, and consumers by empowering consumers to consider packaging as part of a service.

Elements of the project will include: •

new concepts for refill stations

•

packaging leasing and pre-filled reusable containers

•

advanced return points and local bottle washing

•

tracking and analytics

•

a smart consumer app.

Ticking more environmental boxes Sirane has added a new option to its TX (polyester) range - film (or bags) made from at least 30% recycled material. This will tick a lot of environmental boxes for companies facing the forthcoming plastic tax.

Sirane told SPN: “Polyester is a popular choice for ovenable and microwaveable packaging films, as well as a lidding film, and our new material with 30% post-consumer recycled (PCR) material will help a lot of companies tick more environmental boxes.

The product is post-consumer recycled transparent film with one side heat sealable (co-extruded layer with special polymer) and is designed to heat seal on itself as well as with substrates such as A-PET, C-PET; modified C-PET & A-PET coated boards. The film has excellent flatness, dimensional stability, barrier, and high clarity. This grade film is compliant with US FDA, EC, and REACH food contact regulations.

In the UK, a plastic tax is coming into effect in April 2022 on ‘finished packaging’. This tax will levy £200 per tonne on plastic packaging - with some exceptions. One of the exceptions is where it is manufactured from at least 30% recycledplastic - so this product would be exempt from the impending plastic packaging tax.

Simon Balderson, Sirane MD, said: “This development, which allows customers to choose polyester films manufactured from 30% post-consumer recycled materials, is something we have been asked for repeatedly in recent years.

“Because it’s made from 30% recycled materials, it would be exempt from the forthcoming plastic packaging tax, but it also good for companies just looking at ways of improving their environmental credentials.”

For more information, visit: www.sirane.com

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PRO CARTON

Pro Carton

In the Limelight!

An SPN exclusive for Pro Carton: The European Association of Carton and Cartonboard manufacturers From Winfried Muehling, General Manager of Pro Carton “Pro Carton is the European Association of Carton and Cartonboard manufacturers. Its main objective is to promote the use of cartons and cartonboard to brand owners and the trade alike, as well as to designers, the media and politicians as an economically and ecologically-balanced superior packaging medium”.

“The organisation is comprised of 16 members. These represent the vast majority of cartonboard manufacturers and carton producers in Europe. Between them, Pro Carton’s members operate more than 40 production sites and 50 board-machines across 14 European countries. It is the association’s role to work closely with its members and other organisations to provide customers, consumers, retailers and other interested parties the very latest information on the significant benefits of cartonboard.

Renewable, recyclable and biodegradable Cartonboard is one of the most environmentally friendly packaging materials. It uses renewable resources during each production stage and is fully recyclable and biodegradable.

As a result, the recycling rates for cartonboard have reached 84.2% in Europe , thus making it one of the highest rates-ofuse for any packaging material.

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“ Our recent research reveals that fibre-based packaging materials can be recycled more than 25 times ” During the pandemic, consumers around the world became increasingly aware of the environmental impact of their packaging consumption, as well as the end-of-life products that they create. Cartonboard packaging efficiently protects products during transportation from the manufacturing process, right through to the broad network of retailers and end-consumers. Our recent research reveals that fibre-based packaging materials can be recycled more than 25 times with little or no loss of mechanical integrity. The results of this scientific research define the best base for our Circular Economy business model and proves why cartonboard is the preferred packaging solution for around 80% of consumers .

In fact, with rising recycling rates among consumers, new research carried out by Pro Carton in 2021 revealed that 58% of European consumers recycled more packaging than before the pandemic – it is no surprise therefore that cartonboard continues to grow in popularity. It is now evident that consumers in Europe trust cartonboard more than ever, and they fully appreciate its environmental value and recycling capabilities.

PRO CARTON

“ cartonboard packaging solutions provide an excellent example of how to achieve a truly Circular Economy ”

This in turn creates an obligation for cartonboard producers to provide even more efficient and more functional packaging solutions. The good news for consumers and the environment is that global and local brands are both responding well by embracing the functionality and sustainability that cartonboard offers. It is already proven to be a most reliable option for the safe and hygienic transportation of a wide range of products – protecting both the product and the health of the consumer. The focus of the industry’s R&D activities today is to offer an increasing number of applications for cartonboard solutions in entirely new categories. Here, cartonboard manufacturers are consistently improving their barrier properties to offer environmentallyfriendly barrier solutions for products exposed directly to their contact with food.

Furthermore, thanks to its uniquely renewable, recyclable, and biodegradable properties, cartonboard packaging solutions provide an excellent example of how to achieve a truly Circular Economy. Circularity starts with the design of the package by using materials from renewable sources, as well as minimising material usage to meet the functional expectations of consumers. Therefore, it is important to understand this and to plan for more effective recycling processes already during the design stage. Here, cartonboard and carton manufacturers collaborate closely with recyclers to maximise collection and recycling rates. It is our clear ambition to further raise-the-bar in order to increase recycling rates for fibre-based materials to 90% by 2030.

We know that this is an ambitious figure, but with the support of retailers and consumers in Europe we should certainly be able to achieve this.

The Circular Economy also means that we must take full responsibility for ensuring sustainable forest management.

Nearly 78% of wood, woodchips or residues from saw mills we purchase come from forests that are certified.

These have expanded by almost 20 million hectares over the last 30 years , which equals about half the surface area of Germany. Our industry fully supports sustainable forestmanagement as a base for a healthier climate and to secure a constant supply of sustainably-managed raw materials.

At Pro Carton, we passionately support sustainable forestmanagement for cartonboard production and champion clean production processes for both cartonboard and cartons.

Through collaboration and close communication with our members, we help retailers and consumers to secure the highest possible collection rates of end-of-use cartons. Our members continue to invest in new technology to improve recycling rates and maximise the use of recycled materials.

All of these efforts reflect positively on our ambitions and our dedication to lead the packaging industry forward and to further demonstrate how a truly Circular Economy can be made possible”.

For more information on Pro Carton and the outstanding benefits of cartonboard, visit www.procarton.com

SUSTAINABLE PACKAGING NEWS

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E-COMMERCE

Working backwards to go forwards Amazon is a global e-commerce company that takes everything ‘global’ very seriously.

It devotes a large percentage of its profits to reducing waste and protecting the planet.

It is committed to the circular economy and is progressing towards a zero carbon footprint.

In a recent press release Amazon said that designing packaging starts with the customer and works backwards.

It stated that unlike traditional retail stores, products bought online don’t need the excess packaging and plastic materials used for displaying products on store shelves, such as twist-ties, bindings, and clamshell casings.

Frustration-Free Packaging In 2008, Amazon introduced Frustration-Free Packaging (FFP) to help manufacturers reduce packaging waste and develop sustainable alternatives for online fulfillment. Its FFP programs incentivise manufacturers to package their products in easy-to-open packaging that is 100% recyclable and ready to ship to customers without additional Amazon boxes. As of June 2021, Amazon has reduced the weight of outbound packaging by over 36% and has eliminated more than 1 million tons of packaging material since 2015—the equivalent of 2 billion shipping boxes.

Partnering to Reduce Waste Amazon teamed up with Procter & Gamble to invent the Tide Eco-Box, a concentrated version of Tide’s traditional laundry detergent compressed into a fully recyclable, shipping-safe package. It uses 60% less plastic and 30% less water than a conventional plastic container and requires no additional packing materials to ship.

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SPN believes that collaboration is the way forward to greater waste reduction and sustainability. The latest example of the partnership between Amazon and P&G makes the point very clearly.

Image courtesy of Amazon

E-Commerce

Syntegon

Pick of the year

We look at how the latest pick-and-place robots are automating production lines throughout the food industry, adding greater efficiency, safety and reliability than ever before.

Syntegon Technology Product Manager Robotics, Andreas Schildnecht, told SPN, “Robots are an integral part of today’s industrial reality and play an important role in many production processes. In particular, food manufacturers have recognised the competitive advantages of the automated helpers in recent years and are increasingly investing in solutions such as pick-and-place robots. When it comes to packaging, the goal is to achieve more flexibility and efficiency for production, as well as optimal quality assurance for products.

The megatrend automation has been shaping the industry for years and has gained further momentum during the pandemic. Robots have become an indispensable part of many industries. According to the International Federation of Robotics (IFR) , the number of industrial robots has more than tripled during the past decade globally.

They are also steadily conquering new markets such as the food industry. Here, pick-and-place robots have become a key automation solution and are the fastest-growing robotics segment with a 40 percent market share.

Experts predict that the market for pick-and-place robots will triple within the next ten years. The reason for this rapid development is obvious: the integration of robotics solutions provides food manufacturers with urgently needed competitive advantages such as delivery reliability, higher productivity, and food safety. Robots are able to achieve these optimizations because they address three trends of this price sensitive industry at once: flexibility, efficiency, and quality.

“ they address three trends of this price sensitive industry at once ”

SUSTAINABLE PACKAGING NEWS

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E-COMMERCE

Syntegon RPP Robotic Cell

A fast-paced, changing market Today’s market is changing fast; with product cycles becoming increasingly shorter. In order to remain competitive, manufacturers must introduce a wide variety of products in different packaging styles and sizes to market in ever shorter intervals. These frequent changes increase the pressure during production. Pick-and-place robots are able to increase the required flexibility required to perform a product or format change in the packaging line. However, it is often already sufficient to change the end-of-arm (EoA) tool of the robot.

This in turn means that varying products in different formats can be packaged on one line without the risk of downtimes.

Robots with the right EoA tool can handle even delicate products such as cookies, chips, bars, or baked goods.

Equipped with a special module that tilts the cartons during loading, the robots can pack products in a flat or upright position, as is the case with both the Sigpack TTMD Topload cartoner as well as the new robotic pick-and-place platform (RPP) from Syntegon.

As demand increases, another advantage of robotics solutions proves its worth. This is scalability. Food manufacturers can opt for a fully automated packaging line from the outset and use robots to automate feeding, handling, and loading of their products. Alternatively, existing lines can be automated step by step, by delegating production tasks one after another to robots. This opens more options, especially for medium-sized companies, to benefit from the new technology.

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The modular concept of the RPP, for example, allows food manufacturers to add additional robots to their packaging line at a later stage, thus increasing their production output step-by-step.

Pick-and-Place Proficiency Once pick-and-place robots have been integrated into the packaging line, they work quickly, reliably and without interruptions. Unlike humans, they show no signs of fatigue even after many hours of repetitive work.

On the contrary: robots are predestined for monotonous work processes that require reliability and precision at high speed. The integration of pick-and-place robots makes it possible to relieve employees of tiring tasks, such as loading carton boxes or feeding products to the line by hand. As a result, they can take on more complex processes and tasks such as format changes, cleaning and supervision of the line.

The better manufacturers succeed in optimizing the division of tasks between employees and machines in their production, the greater the benefits. Supported by vision control systems, robots detect defective products during production and eject them immediately. This prevents defective products from reaching the market and causing economic or image damage to the brand. At the same time, robotic solutions improve plannability, as downtimes can be scheduled flexibly. Production capacities are used optimally, especially when producing small batch sizes.

E-Commerce

Crystal clear vision If assortment packs are to be assembled, the HD vision system instantly recognises the different unsorted products on the belt and makes sure that the robots can place them in boxes or trays according to specifications set in the HMI. These processes run automatically once they have been programmed. In addition, the robots detect defective products during production and eject them immediately.

To further reduce the risk of contamination, the robot arms are integrated in stainless steel cells whose surfaces are particularly easy to clean.

Unlike painted cells, stainless steel eliminates the risk of paint peeling off and becoming a source of contamination itself. In accordance with the IP65 hygiene standard, the cells of the Syntegon RPP are designed without dead spaces.

Surfaces are angled and therefore self-draining providing optimal hygiene.

Robatech launches adhesive application solutions for e-commerce packaging The Swiss manufacturer of adhesive application solutions presented modular solutions for the rapid application of silicone release liners and tear strips, as well as reliable gluing of on-demand packaging, at the E-Commerce Solutions Showcase from March 15-17, 2022.

Robatech is taking a new approach to the application of pressure sensitive adhesive closures and tear strips by applying PSA adhesive directly to shipping packaging. First, the new Vivo 18 coating head applies the adhesive to the cardboard package with millimeter precision and uniformity. Then, the applicator of a partner company applies the tear strip or silicone paper strip.

“ Pick-and-place robots have taken on a key role in modern production environments ” Factories of the future Pick-and-place robots have taken on a key role in modern production environments. If manufacturers succeed in efficiently integrating these automated helpers into their new or existing packaging lines, they are equipped to meet the demands of a dynamic food market. In the coming years, further developments in robotics and automation will continue to provide manufacturers with more competitive advantages. Hence, the developers at Syntegon are already following a holistic, UX-based approach to deliver automation solutions that are fit for the automated future.

For further details, visit: www.syntegon.com

Unlike with double-sided tape or pre-glued tear strips, speeds of 200–250 m/min are possible with this process. Moreover, packaging manufacturers can reduce their adhesive consumption by up to 30 % with the integrated quantity control. In the case of mailer bags made of film, the adhesive is applied to the silicone paper strip.

The system is easy to operate from the host machine, the applicator or at the melter of the adhesive application system.

For more information visit: www.robatech.com/e-commerce

AS EASY AS THIS Make customers happy with reliable silicone release liners and save up to 30 % on adhesives in packaging production. robatech.com/e-commerce

SUSTAINABLE PACKAGING NEWS

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FOOD PACKAGING

Sustainable packaging licked Huhtamaki, a key global provider of sustainable packaging solutions, has worked with Carte D’Or to shift the packaging for their ice cream to recyclable paper tubs and lids.

The move to recyclable paper-based packaging will help the brand eliminate more than 900 tonnes of virgin plastic in the UK annually. “Huhtamaki is on a journey to becoming the first choice in sustainable packaging solutions with a focus to ensure our products are recyclable, compostable, or reusable by 2030. We are delighted to support Unilever’s ambitions for its packaging portfolio which includes halving the amount of plastic used by 2025 and rethinking plastic packaging to use less, better or no plastic. The shift in packaging for Carte D’Or addresses these key targets. We develop fit-forpurpose packaging that is best suited for the product and the environment. It is also why we continue to innovate with more sustainable packaging, designed to play its role in delivering systemic change,” says Herwin Wichers, Head of Huhtamaki FMCG Category, Fiber Foodservice EAO.

The recyclable paper tubs and lids for the Carte D’Or range use 93% less plastic per tub, this translates to significant reduction in the amount of plastic used annually. This latest packaging solution from Huhtamaki will be introduced in the UK and is made using fibers from PEFC certified sustainably managed forests. The new packaging for Carte D’Or is already available across the UK and will be introduced across their entire 8strong range of ice cream.

“ we continue to innovate with more sustainable packaging, designed to play its role in delivering systemic change ”

WRAP calls for removal of more ‘unnecessary and problematic’ single use plastic items This comes under The UK Plastics Pact and includes wrapping on multi-packs of tinned food and sauce sachets in restaurants.

New research and recommendations from WRAP suggests selling fresh produce ‘loose’ and removing date labels could prevent 14 million shopping baskets worth of food from going to waste and 1,100 waste trucks of ‘avoidable plastic’ simply by allowing people to ‘buy what they need’.

An 18-month project conducted by WRAP, with input from industry, to examine the link between food waste in the home and the use of plastic packaging, has challenged accepted thinking that packaging helps to preserve fresh produce As well as suggesting that selling loose has ‘huge potential’ to reduce food waste in our homes, the research also examined the influence of date labels and storage temperatures on food going to waste.

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SPONSORED

Flexible Packaging - Overcoming Challenges The flexible packaging industry is facing its biggest challenges in possibly a generation. In addition to the well documented ongoing decline in run lengths, which are forcing converters to streamline operations to improve efficiencies, reduce waste and ultimately reduce overall costs, converters now also have to manage general concerns over sustainability and specifically, the concerns around plastic consumer waste.

Consequently, Sun Chemical’s commitment to these technologies has increased so that inks and coatings with bio sourced and/or recycled materials are available to enhance our customers’ environmental profiles.

Fortunately, in recent years, the flexible packaging industry has invested in the latest equipment and embraced emerging technologies, meaning it is now better equipped to overcome new challenges and strengthen its place in the supply chain.

As a leading global supplier of inks, coatings and adhesives, Sun Chemical is developing products, technologies and services that ensure our customers meet their sustainability and operational efficiency goals. In recent years, Sun Chemical’s R&D has focused on sustainability and operational efficiency, so that today, new enabling technologies can be offered to the global market place.

In recent years, the level of consumer concern regarding sustainability has significantly increased and has prompted an increase in demand for more sustainable inks and coatings by packaging converters and brand owners.

Key performance indicators are also published in our annual sustainability report, which can be downloaded at: https://www.sunchemical.com/about/sustainability/sustainability-report/

who can give their flexible packaging the power of sustainability? you can.

The Power of Sustainable Packaging.

Today’s consumers are more environmentally conscious than ever — that’s why we’re committed to innovative flexible packaging solutions that are good for the environment and the bottom line. At Sun Chemical, helping you meet your sustainability goals just comes naturally.

Request your copy of Sun Chemical’s Guide to Sustainable Packaging at sunchemical.com/powerofflexiblepackaging.

working for you.

FOOD PACKAGING

Food packaging within the circular economy Almost two-thirds of the UK’s best-selling branded groceries come in packaging, which is not fully recyclable. That’s according to new research by the product review platform Which? that looked at 89 popular branded groceries across ten top-selling categories of food and drink and found only 34% had packaging that could be fully recycled. This makes for pretty depressing reading, but the packaging world is responding to this with brilliant, innovative design and biobased materials, some of which can even be composted at home.

Natalie Hitchins, Which? Head of Home Products and Services, said: “Consumers are crying out for brands that take sustainability seriously and products that are easy to recycle, but for any real difference to be made to the environment, manufacturers need to maximise their use of recyclable and recycled materials and ensure products are correctly labelled.

“ the government must make labelling mandatory, simple and clear ” “To reduce the waste that goes to landfill, the government must make labelling mandatory, simple and clear, enabling shoppers to know exactly how to dispose of the packaging on the products they consume.”

Coating manufacturer Teknos is developing a new, biobased barrier coating for food packaging together with biosourced materials company Brightplus. The objective of the cooperation is to develop bio-based and biodegradable solutions for more environmentally friendly food packaging.

“By replacing the traditional plastic film with this new biobased barrier coating, we can increase the eco-friendliness of food packaging products. The solution can also enable wider use of fibre-based material in food packaging”, Tuomas Aspiala, Group Commercial Manager, Teknos explains.

Smurfit Kappa has developed a new, entirely sustainable packaging solution for fast food following close collaboration with independent Packaging Consultant Juozas Baranauskas.

The new Fresh Post food box is made from Smurfit Kappa’s Twin Kraft Solid Board, which is a paper-based mono-material specifically designed for food packaging. By integrating the company’s MB12 technology, the recyclable material can adsorb mineral oils, keeping food safe whilst simultaneously protecting aroma and taste.

Commenting on the collaboration, Smurfit Kappa VP of Innovation and Development, Arco Berkenbosch stated: “We work with customers of all sizes to help them realise their sustainability goals and present their products in the best and most sustainable way. We were delighted to work with Juozas on the creation of this innovative and sustainable solution.

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Smurfit Kappa’s Twin Kraft Board won a Packaging Innovation Award in the 2021 RISI PPI Awards and a Pro Carton Innovation Award in 2020

FOOD PACKAGING

“It’s another example of a Better Planet Packaging product with the potential to have a transformative effect on a sector. If all takeaway food providers were to switch to a paper-based material like Twin Kraft Solid Board, the impact would be significant.”

Trivium Packaging are makers of infinitely recyclable metal packaging that delivers convenience, protection, and freshness. Metal has the power to Protect (safeguard contents from external elements and shocks), Promote (serve as platform for brand differentiation and consumer messaging), and Preserve (retain natural resources in closed loops/ systems). Aluminium and steel cans provide the ultimate in food protection and preservation. With processes that can go from harvest to canning in as little as five hours, metal packaging delivers a level of nutrition comparable to that of fresh food without preservatives or refrigeration.

Steel and aluminium cans are also unbreakable, heat and puncture resistant and impervious to oxygen, light and bacteria. There is no more sustainable packaging than metal cans. Aluminium and steel cans can be 100% recycled repeatedly without loss of quality. With 1.3 billion tonnes of food produced for human consumption - a staggering one third of total global food production going to waste each year, canning can play a lead role in the fight against food waste.

Hot Fill rPET

We stay ahead of a constantly moving consumer world by being agile, innovative and passionate about the possibilities of packaging.

Because we know the huge role we play in creating a world that our children – and their children – can enjoy.

From design, tooling manufacturing to extrusion, we take care of everything in-house.

That’s why we do more than simply excel at packaging.

We take packaging personally.

Working each day to be part of the solution, not part of the problem.

www.waddingtoneurope.com E: info@waddingtoneurope.com Tel: +44 1278 410160

SUSTAINABLE PACKAGING NEWS

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FOOD PACKAGING

Sealed Air has expanded its range of recycle-ready barrier display films to help improve recyclability throughout European food supply chains. Two new CRYOVAC® Brand Eco BDF films have been specifically designed for compatibility with both LDPE mechanical recycling and chemical recycling processes. The new range includes Eco BDF20M, which is made from 100% virgin materials and Eco rBDF20M - a barrier display film containing 30% Certified Circular Resins (CCR).

Arnaud Brunet, Food Films Portfolio Director EMEA, at Sealed Air, said: “The APR and PRE protocols are extremely well defined and diligently test the ability to recycle innovative new films alongside pure materials such as polyethylene.

“Recycling strategies are advancing throughout Europe, with infrastructures at various stages of development in different countries. Our aim was to develop new barrier display films that would optimise recycling compatibility across this diverse spectrum. It will help food processors, retailers and brands to improve resourcefulness as countries increasingly heads towards a circular economy.”

Arnaud concludes: “The development of ECO BDF forms part of Sealed Air’s pledge that 100% of its packaging will be recyclable by 2025. This supports our customer’s sustainability goals and is focused on providing them with innovative solutions that align with a circular economy.”

Scientists from Nanyang Technological University (NTU) and Harvard T.H. Chan School of Public Health, U.S. have jointly developed a biodegradable food packaging that can keep fruits fresh longer than the usual synthetic plastic packaging.

The biodegradable food packaging’s main ingredient is zein.

Zein is produced from corn gluten meal which is a waste byproduct from corn starch or oils that are used in ethanol production.

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The food packaging is made by electrospinning an industrial method of using electric force to produce fibres - the zein, natural antimicrobial compounds with cellulose, a natural polymer starch that makes up plant cell walls, and acetic acid.

The result is a waterproof and antimicrobial material.

During lab experiments, the material releases “necessary minuscule” amounts of natural compounds that can kill common food contaminating bacteria such as E. Coli, Listeria, and fungi, when exposed to increased humidity or bacteria.

Director of NTU’s Centre of Antimicrobial Bioengineering, who is also the co-leader of the project, Mary Chan said: “The smart release of antimicrobials only when bacteria or high humidity is present, provides protection only when needed thus minimising the use of chemicals and preserving the natural composition of foods packaged.”

The material’s combative response to harmful microbes means that the packaging can endure several exposures, and last for months, NTU said. The packaging can extend the shelf-life of fresh fruit by two to three days.

An experiment conducted found that strawberries wrapped in thebiodegradable packaging stayed fresh for three more days, as compared to being kept in mainstream plastic boxes, and only developed mould after seven days. Other than strawberries, this biodegradable food packaging can also be used for a large variety of products, including other fruits and fresh produce, ready-to-eat foods, and raw meat.

This is a fantastic innovation and has great potential to reduce food waste and plastic packaging.

With many companies keener than ever to reduce their carbon footprint, and consumers wishing to be proactive about reducing their own impact on the environment, it makes good sense to invest in sustainable food packaging.

SPONSORED

ECO.BANDING® The solution for new sustainability guidelines The ECO.BANDING® allows you to package your fruits and vegetables food safe using FSC certified paper. With this certification you can be sure all materials in your packaging are well sourced. The ECO.BANDING® is made of 98% paper and the ECO.SEAL®. The band is 100% recyclable.

Flexible advantages By using Bandall Banding Machines in combination with the ECO. BANDING® you benefit from many advantages such as flexible printing directly onto the band and the Multi-Width option. With the Multi-Width option you are able to process multiple band widths on just one machine resulting in even more sustainabilty for your company.

Bandall

Consumers want companies to operate more sustainably, and governments are tightening their rules around the topic. France has already introduced the AGEC law that has banned the use of all plastics in the packaging of fruits & vegetables and Spain is planning on following this example in 2023. The solution for all these new guidelines is the ECO.BANDING®.

Bandall develops, manufactures and distributes banding and bundling machines worldwide. With the use of these machines a reduction of 80% or more in packaging materials and waste can be achieved. From manual to fully automatic machines; Bandall machines are incredibly flexible and have a wide range of applications.

The ECO.BANDING® is offered in collaboration with Specialist Printer Max. Aarts.

Banding for sustainability › 100% recyclable ECO.BANDING (paper banding which complies with French and European guidelines) › Stand Alone and bespoke fully automatic solutions › Waste reductions of 80 % or more are no exception › Flexible printing while banding

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Meet us at Seafood Brussels, Label Expo, Anuga FoodTec or Fruit Logistica T +31 (0)348 431520 E info@bandall.com I bandall.com ›

FOOD PACKAGING

SP GROUP

Commitment to sustainability Sustainability is currently a major concern around the world. We are seeing that consumers clearly prefer sustainable products in recyclable, eco-friendly packaging.

In fact, in its UK study performed in 2021, Deloitte highlighted that one in three consumers had stopped buying certain products due to sustainability issues and brand ethics.

At SP GROUP we are very familiar with the concept. Some years ago, we decided to embrace the movement and commit to sustainability. As a result, we have become pioneers in innovation in this area, and we have developed new materials and solutions that provide packaging options that are more sustainable than traditional packaging.

We have worked hard to create the best applications for our clients. Our goal is to offer truly sustainable solutions that maintain the properties of traditional structures and make sustainable transformation a reality.

However, we took a step even further in this direction.

We decided this change didn’t just need to affect the final product – it had to permeate the process from beginning to end.

And we achieved our objective, incorporating the three Rs into our production process: reduce, reuse and recycle. This led to the creation of four areas of research and development: the production of mono-material solutions that facilitate the recycling process, the incorporation of recycled material into the production process, the creation of materials that reduce the carbon footprint and the creation of biodegradable films.

The resulting solutions form part of our ECO range, including our PE ECO, PE HB ECO and PP HB ECO materials. These applications are 100%-recyclable mono-materials. All of them can withstand heat treatments such as hot-fill and pasteurisation, with the advantage that PP HB ECO is also retortable.

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Both PP HB ECO and PE HB ECO can be used to replace other non-recyclable packaging and multi-material structures for all kinds of sectors, and all are suitable for food use. These are sustainable, effective and versatile packaging alternatives.

It is also important to mention SOL EFFICIENT which, together with our rPET tray film, provides a very sustainable solution that is popular in sectors including the meat industry.

RCLOSING HB EFFICIENT is also popular in this industry, as it can be used to make resealable lids for cold cuts.

As well as this commitment to sustainability, there are new EC directives on recyclability that have led to a revolution in the sector and which motivate us to keep working on more sustainable solutions.

SP GROUP will continue to work to ensure this sustainablepackaging revolution becomes a reality. In fact, we have already set our new goal: to obtain RESIDUO CERO (ZERO WASTE) certification.

To achieve this goal, we started several different projects and initiatives three years ago. One example is our Project Zero Wastage, which aims to reduce excess waste from production on the (PA/PE) multi-layer coextrusion line by reintroducing it into the manufacturing process. Another is our Sustainable Pallets project, which involved buying a machine to make our own plastic pallets from waste generated at the factory.

These pallets are ideal for transporting a variety of different loads. For everyone at SP GROUP, sustainability is a real commitment to the future.

SPONSORED

Precision-banding is saving materials…and costs E-commerce is booming and the two big trends and drivers in fulfillment are automation and sustainability. Banding is the packaging technology of the moment and it provides the answer to numerous challenges in the fulfillment process.

The amount of packaging material generated in the fulfillment process is enormous. Many 3PLs and captive logistics centres have identified ‘right-size-packaging’ as a means of reducing packaging materials and costs. One option is to use box-on-demand packaging machines that process a corrugated material commonly known as fanfold (also known as endless board or z-fold). Because the shipping boxes are cut to the precise size of the products to be shipped, no air is packed and therefore no additional material is needed for filling voids.

Alternatively, bands can also be used instead of strapping for sealing shipping cartons – especially ideal for heavier igoods such as pet food, furniture, car accessories or household goods. Unlike strapping, the wide bands do not damage the shipping cartons and at the same time facilitate safe handling all the way to the end customer.

Two areas where banding simplifies right-size-packaging

Optimising warehousing and returns-logistics

On the one hand, banding is used to bundle multi-item orders into units. This can be achieved by using either semi, or fully automatic methods, or in addition, it can be used to attach individual products to cartons. The bands hold the units together on the conveyor belt all the way to the packaging machine and provide a secure hold in the on-demand produced shipping carton.

Banding can also optimise warehousing. For example, bands made of paper are able to hold on the lids of shoe boxes in place, thus enabling valuable space-saving storage. What’s more, they can facilitate returnshandling by taking on the role of providing tamper proof evidence: Returned shoe boxes with intact bands can also be returned directly to the warehouse without inspection. As ATS-Tanner says, together these clear benefits make a very strong arguement for adopting flexible banding technology for so many reasons, not least that it saves significant amounts of packaging materials.

If required, the bands can be printed just-in-time with variable information such as scannable QR codes to digitize processes.

Learn how to reduce packaging and automate your processes with banding.

ats-tanner.com

FOOD PACKAGING

kp Elite

®

Unique recyclable MAP solution kp Elite® offers this modified atmosphere packaging (MAP) solution for fresh protein that delivers end-to-end sustainability.

This award-winning product is made with up to 100% recycled PET (rPET), which is recyclable, highly efficient, reduces food waste and extends shelf-life.

• Recyclable tray (mono material)* • Seals through contamination • Reduction in sealing time and temperature • Hermetic seal, reduced leakage • Made with up to 100% recycled PET • Very low carbon footprint • Maximum strength with minimum weight

*Easily sorted and recycled where the right infrastructure is in place. © 2022 Klöckner Pentaplast. All rights reserved.

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kpfilms.com

Sustainable protection of everyday needs

FOOD PACKAGING

AMCOR

Increasing lifespan

In February this year, Amcor announced the launch of their new ground-breaking, LifeSpan® High-Performance Paper. This advanced paper formula offers food packaging companies a wide range of fully recyclable, high-barrier paper-based solutions.

Amcor’s LifeSpan® Performance Paper is a new recyclable paper-based solution with a high oxygen and moisture barrier. With over 80% recovered content it’s fully recyclable in most countries worldwide. The product’s PVDC-free high barrier delivers product freshness, with comparable barrier level to metallised OPP plastic solutions. It has a wide range of diverse applications that includes Snack Bars, Biscuits, Cookies, Cereals, Fruit, Vegetables and beverages, to name but a few.

“ It makes the switch from plastic to paper simple and easy ” LifeSpan Performance Paper has also been tested with several leading FMCG brands, with excellent machine performance results. It makes the switch from plastic to paper simple and easy.

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FOOD PACKAGING

Customer benefits offer Recyclability in existing paper streams, as well as the potential to help brands lower the impact of upcoming EPR changes & plastic taxes.

What’s more, the paper-based structure is optimised to achieve excellent machine speed. Another considerable benefit is that it offers unique, high-barrier properties for paper, particularly in relation to water vapour and for grease resistance.

Lifespan consumer benefits The product’s wide range of performance-paper solutions appeals to consumers and helps products enjoy greater shelf appeal. It also offers high barrier and grease resistant benefits that provide excellent product presentation opportunities. Furthermore, LifeSpan Performance Paper is recyclable across the majority of EU paper streams and is available with FSC® certified paper. The paper structure is also made from only from approved, bio-based materials.

SPN knows that many companies such as WestPak for example, have already seen the benefits that the latest Amcor offering provides. What’s more, with its broad ranging product appeal, there will doubtless be countless other packaging companies following suit!

New, more friendly Crisps!

Two UK potato farmers armers have joined forces to produce more environmentally friendly crisps. Farmer friends Mark Green and Sean Mason grow and market potatoes and together have started a business venture making environmentally-friendly crisps.

In 2014 the farmers, from Herefordshire, decided to start working together and spent the next few years developing a crisps brand with sustainability running through its core.

The crisps are packaged in compostable packaging, food delivery miles are kept to a minimum and all the crisps are made from potatoes grown by the farmers themselves.

“ Total investment to date is more than £500k ” However, investment has spiralled past their initial estimations and to mitigate costs they have taken their brand of crisps to market themselves. Total investment to date is more than £500k. We wish them every success as we know that the demand is there!

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Reusable Packaging

PakTech

Encircled

PakTech is a US designer and manufacturer of fully recyclable injection moulded handles. It is dedicated to the principles of the circular economy. As a result, all its handles are made from 100% recycled HDPE. They are designed specifically for the food, beverage, and consumer goods industries.

PakTech is universally known for its dedication to creating a sustainable future by enabling the transition towards a global circular economy. Therefore, all handles produced by PakTech perfectly embody the circular economy principles, and are all made from 100% recycled HDPE. This makes them reusable up to 40 times and completely recyclable. The company has made the conscious decision to choose HDPE as a material of their choice as it is one of the safest and most toxic-free materials available. Furthermore, by using a single material to produce their handles, PakTech packaging solutions are designed from the start for recycling.

Founded in 1991, PakTech is an industry leader in using recycled HDPE plastic to create 100% recyclable packaging handles and automated application equipment.

Headquartered in Eugene, Oregon, PakTech is a full-service company that specializes in creating injection molded handles for multi-packing products. PakTech makes it easy for consumers to grab, carry, and release multiple products using a simple, minimal, 100% recyclable handle.

So far, PakTech has kept more than 45,119,288 kg of plastic out of the environment and within the circular economy by using discarded plastic waste to produce their handles. It is also worth noting that they’ve recently set up a warehouse in Rotterdam to further improve their services to their EU clients.

A grip on the future Pak Tech told SPN. “With the increasing prominence of online shopping, consumers have begun to realise something that businesses have known for a long time, that a lot of packaging is wasted. Today, governments, businesses and consumers look for ways to optimise waste management. Among different solutions, the waste hierarchy concept has become an essential tool to determine priorities for action to reduce and manage waste sustainably. Yet, this concept remains unknown to many.

Today, packaging trends have shifted considerably, as consumers are rethinking their packaging choices, re-evaluating their purchasing habits and educating themselves on sustainable practices. Similarly, producers are accommodating consumers’ preferences into their products by investing in advanced technologies, working with different materials and techniques and setting ambitious environmental targets. Brands, distributors, and retailers are increasingly becoming more selective with the type of packaging solution they choose to offer.

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Reusable Packaging

Reusable Packaging

Ways in which taking advantage of a returnable supply chain can actually minimise your company’s environmental impact.

The three R’s. Reduce, Reuse, Recycle. We frequently skip the first two steps and proceed directly to recycle. According to the World Economic Forum, just 14% of plastic packaging is collected for recycling globally, and due to complexities in the recycling process, huge amounts of single-use plastic (as well as glass and cardboard) that consumers try to recycle ultimately end up getting incinerated or thrown into landfill anyway. If recyclable materials are contaminated by food waste, or if consumers misunderstand what can be recycled and where—to cite two common examples—their recycling may not end up being repurposed after all.

E-commerce is quickly becoming a major ecological issue, although the potential the Internet has to save material and energy cannot be denied, each potential positive impact is coupled with a potentially overwhelming negative impact.

More than one billion parcels are shipped in France each year. Instead of waste, La Poste turned this into a one billion opportunity! While La Poste has already been working for several years to reduce the empty space inside parcels and reduce the carbon footprint of transportation, several challenges remain to make e-commerce shipments kinder to the planet. The latest initiative is to enable the broader use of reusable packaging.

Reusable packaging - being more durable and robust also tends to offer better protection of the products or parts within.

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Consumer demand is leaning toward reusable packaging, but this option is generally the most costly for the customer.

La Poste’s new set-up will industrialise empty packaging return as much as possible, reducing processing costs and therefore making reusable packaging more accessible to online businesses and their customers. By helping make reusable packaging as competitive as single-use packaging, La Poste is unlocking a huge opportunity for reuse in e-commerce.

Reusable packaging providers such as RePack will offer this service to more brands and their customers.

“ The addition of reusable products to our packaging can pack a powerful punch ” FedEx Express have also introduced reusable packaging to its portfolio to reduce waste and promote re-use during returns. “The addition of reusable products to our packaging portfolio can pack a powerful punch if it promotes a positive shift in how end-user consumers think and behave.

While eCommerce returns cannot always be avoided, we see a growing consumer awareness around reducing and reusing packaging. The Reusable Pak is one way we can make sustainable choices easier for our customers and their customers, by putting a solution that minimises packaging waste into their hands,” said David Canavan, Chief Operating Officer, FedEx Express Europe.

Reusable Packaging

Antalis Packaging’s reusable pack design reduced waste and increased efficiency in the distribution of car parts for an Aluminium die casting company manufacturing automotive parts. The Aluminium die casting company, who ship consignments of car parts to another company within the automotive supply chain on a regular basis, required durable and reusable packaging for the distribution of awkwardly shaped car parts.

Previously, the client was having to wrap each car part in bubble wrap before placing in individual boxes, an inefficient solution for both them and the recipient. In an effort to reduce waste and increase efficiency, they required a packaging solution that could be used multiple times, would be easy to pack and unpack, and would be resistant to damp in order to protect the car parts inside.

Todd Smith, Antalis Packaging Technologist, comments “The client was keen to have a packaging solution that would be efficient to use and that could be retained in a constant loop to minimise waste. The key to the packaging design was finding a way to stabilise the parts in a way that meant they could also be stacked. After making a few samples on the CAD table at our Smart Packaging Centre, we came up with the solution that fulfilled all the needs. Our knowledge of packaging materials led us to propose Correx for its versatility, durability, and water resistance.”

Specific reusable packaging – such as Correx® – can also offer weight and volume savings, both of which can also help with reducing transport emissions. In partnership with global reusable packaging platform, Loop, customers in ten large Tesco stores in the east of England will be able to buy products in reusable packaging that can be returned to store when finished “so it can be cleaned, refilled and used again”.

Customers wishing to opt for reusable packaging simply visit the Loop fixture in the store and add the products they want into their trolley as a part of their shop. The Loop range comes ready prefilled in the perfect container for that product, so there’s no need for customers to bring their own containers or refill themselves. Prices for the contents of each item are comparable to the original. A fully refundable deposit starting at £0.20 is paid on each reusable product at checkout and this is refunded via an app when the customer returns the packaging to a collection point in the store.

“ we hope to scale reuse across more stores ” Tom Szaky, founder and CEO of Loop and TerraCycle, said: “The consumer reaction to Loop in these first Tesco stores will prove pivotal in refining the Loop offering and ultimately we hope to scale reuse across more stores and the number of product lines available. Tesco is the perfect partner to bring Loop to retail in the UK due to its commitment to sustainability, in combating plastics waste and in its operational scale as the UK’s biggest grocery retailer.”

Ken Murphy, Tesco Group CEO, said: “We are determined to tackle plastic waste and one of the ways we can help is by improving reuse options available to customers. Bringing Loop to our stores is a significant milestone in this journey. With 88 everyday products available, we’re giving customers a wide range of options and we’ll learn as much as we can from this to inform our future packaging plans.”

In the cosmetics sector, companies that were already devoted to vegan, organic or cruelty-free products tend to reflect their sustainability aims also in packaging. After initial experience with refilling more than 15 years ago that failed due to lack of consumer acceptance, The Body Shop, now under the leadership of the Brazilian brand Natura, is accelerating their sustainability strategy and re-introducing reusable and also refillable packaging. The Body Shop joined Loop using reusable packaging and is reintroducing refillable machines in London. “recycling our way out of [the climate crisis] will not work,” says Sander Defruyt, who runs plastic innovation initiatives at the Ellen MacArthur Foundation (EMF), a sustainabilityfocused nonprofit. “Reuse, as well as plain elimination of a lot of packaging we don’t need, will also have to be a crucial part of the solution.”

Reuse is not new. Reusable forms of packaging have historically been used in a lot of applications and are still found, both in B2B (Business-to-Business, including secondary or transport packaging, e.g. crates, pallets) and in B2C (Business-to-Consumer; also called primary packaging, e.g. beer bottles). However, in the past decades, we have observed a shift away from reusable packaging towards single use. There is growing interest around the world in addressing the sustainability challenges of reducing packaging material.

Seeing the impact of packaging in the environment, means consumers are asking for less wasteful, more eco-friendly options. Reusable packaging systems seem to demonstrate environmental and potential economic benefits over singleuse packaging systems.

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Reusable Packaging

Coca-Cola aims for 100% re-usable

The Coca Cola Company has pledged that by 2030, it aims to have at least 25% of all beverages globally to be sold in refillable/returnable glass or plastic bottles, or in refillable containers through “traditional fountain or Coca-Cola Freestyle dispensers”.

Coca-Cola said that it would expand the rollout of its ‘Universal Bottle’ which is said to offer multiple brands a single reusable bottle in the same colour, shape and size.

It will also expand the rollout of its refillable 2 litre and 1.5 litre PET plastic bottles. The company is also partnering with Carrefour and Loop in France to pilot a circular shopping system. It is also linking up with Burger King and TerraCycle in the US on another pilot programme. Coca-Cola also announced it is to introduce reusable cups with microchip technology for its Freestyle machines. These will be used at theme parks, university campuses and cruise ships.

‘World Without Waste’ goal Elaine Bowers Coventry, chief customer and commercial officer at The Coca-Cola Company said: “We continue to put consumers at the centre of all we do. One way to do that is by offering sustainable packaging types. Accelerating use of reusable packages provides added value for consumers and customers while supporting our World Without Waste goal to collect a bottle or can for every one we sell by 2030.”

New Re-use business model Responding to Coca-Cola’s pledge, Sander Defruyt, The Ellen MacArthur Foundation’s new plastics economy lead, said: “We know we cannot recycle our way out of the plastic pollution crisis, so reuse business models are crucial in a circular economy for packaging. So far, there has been a lack of ambitious activity to scale reuse models across the industry.

The Coca-Cola Company is the first major brand to put in place a company-wide reuse commitment, a significant and welcome move. We hope this will inspire others to recognise the reuse opportunity in their own strategies.”

“ the move will promote a circular economy ” Coca-Cola added that the move will promote a circular economy and said that “refillable containers have high levels of collection and are low-carbon footprint beverage containers, because the container collection is built into the beverage delivery model”.

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Returnable glass bottles and refillable PET currently represent more than 50% of Coca-Cola’s product sales in more than 20 markets, and more than 25% of sales in another 20 markets.

Ben Jordan, senior director, packaging and climate at The Coca-Cola Company, added: “Reusable packaging is among the most effective ways to reduce waste, use fewer resources and lower our carbon footprint in support of a circular economy.

We will continue to highlight markets that are leading the way with reusable packaging best practices, and to support other markets as they increase their use of reusable packaging.”

SPN concluded: “The Coca Cola Company is still setting the benchmark standards - and the pace when it comes to reusable packaging. What’s more it’s being applied across the board in relation to its entire product portfolio.

The medium and long-term benefits are clear for all to see and the contribution towards achieving a global circular economy is further strengthened by the company’s unwavering commitment”

RESOURCE EFFICIENCY IFE MANUFACTURING 2022

Sustainable packaging takes centre stage at IFE Manufacturing 2022 IFE Manufacturing will launch at ExCeL London on 21-23 March 2022 alongside IFE, International Food & Drink Event, The London Produce Show and Hotel, Restaurant & Catering (HRC), creating the UK’s biggest gathering for the food, drink and hospitality industry.

Thousands of food & drink brands will descend on ExCeL London to hear about the future of the food production sector, gain insights into the latest developments in the global supply chain and discover some of the most exciting innovations in the world of packaging for food & drink.

IFE Manufacturing will be showcasing a wide range of innovative suppliers specialising in bespoke, sustainable packaging, from compostable packaging specialists like BioPak and TIPA Compostable Packaging, to providers of bespoke glass containers such as Rawlings Glass Specialists and Blueglass of Sweden, to 100% recycled plastic products from Alison Handling Services, and much more.

Industry leading seminar programme The show’s Innovation Platform will provide visitors to the show with the opportunity to learn first-hand about some of the most exciting developments in the global packaging sector and hear from the creative and inspirational industry leaders operating in food and drink production. Spaces are limited in these thought leadership sessions, so secure your place at ifemanufacturing. co.uk/seminar-programme.

Day One will kick off with Will Cowling, Marketing Manager at FMCG Gurus, as he runs through the packaging trends set to define 2022 and beyond. Cowling comments: “Consumer attitudes towards packaging have become more complex and considered over the last eighteen months, as the role of packaging within the food and drink industry has been re-evaluated.

“Concerns about the impact that packaging has on the environment remain strong, however, at the same time, a greater emphasis on product safety along the supply chain means that more favourable perceptions towards packaging are occurring – something that is directly influencing purchasing.”

This will be followed by a session entitled ‘Where next for sustainable packaging?’ as David Harding-Brown of The Packaging Collective, Andy Sweetman, Sales and Marketing Director at Futamura and Hugh Lewis, Head of Proposition Strategy at Gousto, take to the stage to discuss some of the very latest developments and innovations in the sector.

Day Two of the show will see Gary Tee of TIPA Compostable Packaging, discuss the advances that allow compostable materials to mimic conventional plastic and demonstrate how food and drinks businesses can minimise food waste while choosing materials to benefit our ecosystem.

Where the food & drink industry meets IFE Manufacturing is an unmissable meeting place for businesses interested in advancing their knowledge of the latest packaging innovations in food & drink, making strong, lasting connections in the sector and elevating their product ranges.

Visitors to IFE Manufacturing will have the opportunity to take advantage of the show’s Certification Clinic and Advice-to-Go Zone, where they will be able to meet with organisations including B Lab, City Harvest, SALSA, Fairtrade and many more, all of whom will be offering bespoke advice and guidance.

The Future Food Stage at IFE Manufacturing’s sister event, IFE, will also play host to the World Food Innovation Awards, in partnership with FoodBev Media, as the winners are revealed for 2022. Each year the awards are an exciting glimpse into the future of food & drink, from effective CSR and sustainability initiatives to creative new concepts in packaging design and convenience packaging.

Buyer Julia Lodi, NPD Packaging Technologist at Tate & Lyle Sugars, comments: “After two years of pandemic, I’m looking forward to interacting with the main movers and shakers in our industry, to see the new trends and innovations that these complex times have allowed us to develop.”

Join the who’s who of the food & drink industry at IFE Manufacturing 2022, register to attend at ifemanufacturing.co.uk

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Discover the future of food at IFE Manufacturing There has never been a better time for progressive food and drink industry professionals to come together and be at the forefront of the future of food development.

If you’re responsible for sourcing products and solutions across the food and drink supply chain such as ingredients, packaging solutions, processing and packing technology and manufacturing services, then you need to be at IFE Manufacturing, the UK’s only dedicated showcase for end-to-end food and drink manufacturers.

Don’t miss out!

This unique event will provide you with the tools and knowledge to help drive your business to success in 2022 and beyond.

Scan the QR code to secure your free pass to attend

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