SPN June 2024 by spnews.com

SUSTAINABLE PACKAGING NEWS

Sustainability in FMCG

Speeding up the greening of FMCG packaging. Initiatives to improve sustainability. Taking

New Bioplastics

The growing demand for eco-friendly materials

Waste Management

Green Adhesives

Recyclability

AI = Supply Chain

SmartCycle®

Sustainable Label Films

Close the loop with our recyclable, heat shrink sleeve films produced with 30% post-consumer recycled content!

Samples

Welcome to

Dear Readers,

I hope that all is well with you now that the holiday season is finally upon us. Hopefully there will be some sunshine on offer before the Autumn arrives!

In the meantime, the packaging industry continues to strive to make all aspects of manufacturing and logistics more sustainable than ever before. Having the latest tools to employ smarter practices and the ability to gain greener credentials for your company is a vital goal for everyone in our highly competitive marketplace. As always, SPN is here to provide you with a broad range of current topics and sound advice on how to stay ahead of the game - and that of the competition.

In this our latest issue, we offer some major insights into how companies are embracing the benefits of AI and optimising their contribution towards a greener planet. Here we also focus on Sustainability in the FMCG sector and cover the latest developments in the move over to Paper Packaging.

Furthermore, you will notice that the revolution taking place in the Bioplastics arena is fast gaining ground - and making a difference!

In any event, be sure to take good care and know that everyone here is wishing you every success in the months ahead. You can rely on the fact that SPN has its finger on the pulse, as well as to what matters most in the packaging industry today!

Sincerely,

Philip Yorke ( Editor )

Supply-chain Sleuths

AI driving supply chain efficiency

As food and beverage manufacturers incorporate artificial intelligence into more facets of their operations to give them an advantage in the marketplace, they are spending big money to have access to the latest AI technology.

Microsoft and Coca-Cola joined together four years ago, but since then the capabilities of AI have grown exponentially - a big reason why it is committing to spend nearly five times more than before.

Coca-Cola turning to Microsoft’s AI services

The beverage giant signed a $1.1 billion deal as it explores the use of AI to streamline operations, boost efficiency and more. Coca-Cola signed a $1.1 billion five-year deal with Microsoft to use the technology company’s cloud computing and artificial intelligence services.

Coca-Cola has been innovating with generative AI for nearly a year and has turned to Microsoft’s Azure OpenAI Service for its supply chain, manufacturing and marketing. The beverage giant said it is exploring the use of AI to improve customer experiences, streamline operations, foster innovation, improve its competitive advantage, boost efficiency and discover growth opportunities.

Coca-Cola previously signed a five-year deal in 2020 for $250 million to use Microsoft’s cloud and business software.

“This new agreement builds on the success of Coca-Cola’s partnership strategy with Microsoft, showing our commitment to ongoing digital transformation,” John Murphy, president and chief financial officer at Coca-Cola, said in a statement.

In 2023, Coca-Cola named Pratik Thakar as its global head of generative AI. The Sprite, Diet Coke and BodyArmor maker is using AI as a tool to connect with consumers. Last year, it launched Coca-Cola Y3000, a beverage the company said is the first flavour co-created with humans and AI. It also has used the technology to launch several experiential marketing campaigns.

Coca-Cola is not the only company utilising AI. Mars, AB InBev and McCormick & Co. also are incorporating it into their operations.

- Excerpts first Published June 2024 - Christopher Doering

20-20 Vision

Reducing the food value-chain footprint

The Contribution of Packaging to Reducing CO2 Footprint in the Food Value Chain must increase. With heat waves of unknown length and heat records in many countries the 2022/3 summers have made global warming very much more real. This has an impact on all of us. Greenhouse gas (GHG) emission is the main contributor to global warming. Let’s see how that links to food waste and packaging.

Dr Thomas Groner founded TG Pack Solutions in 2021 and recently told SPN: “Unfortunately, one third of the global food production ends up in the rubbish bin year on year. Studies show that in industrialised countries the majority of food waste is occurring at retail and consumer level. In large cities like London even more than 40% of the food purchased by consumers ends up uneaten in the bin. The FAO estimates that 1,3 billion tons of food is wasted every year. This is more than three times the amount of food required to feed all the app. 800 million people on the planet which are starving. As FAO Director Ren Wang pointed out, we need an area as big as China to produce the food which never gets eaten.

The production and disposal of these 1,3 billion tons of food waste generates an enormous amount of GHG emissions in the magnitude of 4,4 gigatons CO2 equivalent annually. This is about 8 % of the man-made GHG emissions.

If food wastage would be a country, its annual GHG emissions would rank number 3 in the world after the USA before India or to make another comparison the global emissions caused by food wastage equals nearly the emissions of the global road transportations.

Packaging’s role

What can packaging do here? Adequate packaging preserves food and therefore can help to reduce food waste. Circumstances of living and consumption have changed over the last years: we have more elderly people, more single households, people live over the week close to work and at the weekend with the families at a different place. In these situations, packed food - for example in small sizes - can reduce food waste, because the packed food can be eaten completely before it becomes unconsumable.

One might argue that this packaging also has a CO2 footprint. This is correct, however studies of Denkstatt and ifeu show that packaging is only 1% of our CO2 footprint whereas food contributes to 15% of our CO2 footprint. Typically for packed food the food itself accounts for more than 98% and the packaging for less than 2% of the total CO2 footprint of the packed food.

Optimised flexibility

Optimised packaging allowing longer shelf life can reduce food waste in supermarkets and households significantly. Denkstatt has analysed data for cucumbers, meat and cheese. It was clearly shown that adequate and optimised flexible packaging has reduced the total CO2 footprint significantly. The reduction in food waste due to longer shelf life gives a much higher reduction of CO2 equivalents compared to the little additional CO2 equivalents for the flexible packaging.

Here is one example, wrapping a cucumber with thin PE film extended the shelf life in store from 3 to 14 days and consequently has halved the waste of unconsumable cumbers in supermarkets. The saving on waste is a saving of 13,5 g CO2 equivalent per cucumber whilst the thin PE film creates only 4,4 g CO2 equivalent per cucumber, this gives a net saving of more than 9 g CO2 equivalent for each cucumber wrapped in thin PE film. This is not even counting the reduced food waste in households, these benefits come on top.

But is all packaging the same? A study done by the Institute for Energy and Environmental Research (ifeu) analysed different packaging for 125 g olives and 400 g past sauce: steel can, glass jar and flexible plastic pouch. In both cases the CO2 footprint of the flexible plastic pouch was only a third of the CO2 footprint of the best rigid packaging. Here the glass jar scored better than the steel can. Interestingly the huge advantage for flexible plastic pouches exists at current recycling rates for steel, glass and flexibles as well as at assumed 100% recycling rates for all three”.

For more information visit: www.tgpacksolutions.com

New Centre of Excellence for “Bright Minds”

Amcor’s new European Innovation Centre brings brands the latest in material science and packaging design. Located in Belgium, the new centre of excellence will partner with brands and retailers from across the region to design packaging that delivers the best possible results for consumers and the environment.

“ The opening of the Amcor Innovation Centre Europe is a significant investment towards more sustainable, circular, and innovative packaging ”

Amcor, a global leader in developing and producing responsible packaging solutions, has expanded its packaging innovation hubs around the world. In addition to existing centres in the US, South America and Asia Pacific, the company has now opened its Amcor Innovation Centre Europe (AICE) in Ghent, Belgium. The AICE will pioneer new material technologies to make packaging more sustainable and performant, while focusing on designs that stand out in shops and increase ease-of-use for consumers.

“The opening of the Amcor Innovation Centre Europe is a significant investment towards more sustainable, circular, and innovative packaging,” said Michael Zacka, President Amcor Flexibles Europe, Middle East, and Africa. “The centre brings together the brightest minds in packaging design, material science and state-of-the-art technology to offer our customers a complete brand solution, from concept to commercial launch.”

Image courtesy Amcor

“ Amcor has set ambitious sustainability goals for itself. It has pledged to develop all its packaging to be recyclable, compostable or reusable by 2025 ”

Catalyst Approach

In its Innovation Centre Europe, Amcor supports brands from concept to shelf using its Catalyst™ approach. This flexible, collaborative, and creative co-development methodology creates packaging solutions that take into account a brand’s market, consumer needs, sustainability and recyclability requirements, and customers’ existing production lines. To support this end-to-end collaborative process, the AICE facilitates a range of activities:

The Material Science Centre creates innovative packaging materials that can drive down packaging’s carbon footprint; for instance, by introducing recycle-ready mono-material solutions that can match the performance of common mixedmaterial solutions; or switching to bio-based and recycled polymer alternatives. The center also supports developments in high-barrier paper packaging and vapor-deposited nanocoating. In the analytical labs, new materials are tested using the most advanced techniques.

The Customer Engagement Centre supports collaborative sessions and boasts an observation room for consumer focus groups. Packaging appeal and usability can be tested in an on-site retail simulation area, plus in kitchen, living room and bathroom settings where consumers and marketers alike can interact with packaging. The on-site prototyping lab can quickly create different packaging solutions for test participants to try out.

The E-Commerce Lab tests and certifies packaging according to ISTA 6 standards, to validate packaging for shipment through Amazon and other ecommerce distribution chains.

The Packaging and Recycling Test Centre will house smallscale packing lines which mimic brands’ own packing lines for in-house machine trials. Recycling equipment will allow Amcor

“We want to create packaging that consumers like, and that is better for the environment,” said Noemi Bertolino, Vice President Research & Development. “The packaging needs to look appealing, and be easy to open, portion and close. It also needs to be suitable for current and future collection, sorting and recycling infrastructure. At the AICE, we can test packaging against these requirements. For example, in our Customer Engagement Centre, we can test whether a child-resistant push-through blister pack for pharmaceuticals is easy for an adult with arthritis to open.”

Ambitious Sustainability Goals

Amcor has set ambitious sustainability goals for itself. It has pledged to develop all its packaging to be recyclable, compostable or reusable by 2025, and to significantly increase its use of recycled materials. In line with this sustainability commitment, the Amcor Innovation Centre Europe is housed in a building that is designed and built according to BREEAM sustainability certification standards.

Michael Zacka, President Amcor Flexibles EMEA (left) and Noemi Bertolino, Vice President R&D (right) cut the ribbon on the new Amcor Innovation Centre Europe.

Intelligent energy management for a net zero world

Whether working in automotive or logistics, fast-moving consumer goods (FMCS) or food and drink, some factory managers can take an ‘if it ain’t broke, don’t fix it’ view. This approach is understandable, particularly if it relates to a process that took a long time to get right in the first place, or a line or machine that is running reliably.

However, reducing Scope 1 greenhouse gas (GHG) emissions in the order of magnitude necessary to meet 2050 targets will entail the modification of many existing plants and processes – even those that are working perfectly. Luckily, we do not need to start from scratch to achieve our goals. Intelligent energy management, or the optimisation of energy use within an organisation, can help identify potential areas of improvement, and guide the adoption of practical, feasible ways to decarbonise operations. Here, Sam Tilley, Regional General Manager (UK, Ireland & Nordics), at OMRON, shares a few examples.

Materials handling and GHG emissions

A single forklift generates around 2,640 grams of carbon dioxide (CO2) per litre of diesel combusted, resulting in between 5,280 and 7,920 grams of CO2 emissions an hour. Opting for more sustainable methods of on-site materials handling, then, could represent a significant GHG saving. Autonomous mobile robots (AMRs) are battery powered, making them the perfect fossil-free alternative for transporting boxes and pallets. They are also intelligent enough to return to the charging station when they need to, optimising workflows even further.

They also represent a dynamic replacement for conventional linear conveyors. What’s more, unlike traditional autonomously guided vehicles (AGVs), they require no facility modifications, such as floor magnets or navigational beacons, making them relatively simple to adopt.

Robotics can also drive greater energy efficiency in palletising, where the rise of e-commerce and the trend towards high mix low volume (HMLV) manufacturing has made mixed pallets more common.

With fewer pallets equalling lower per unit carbon emissions, optimising the various patterns to make better use of space in transit and storage requires complex programming.

Sam Tilley, Regional General Manager (UK, Ireland & Nordics) at OMRON

Collaborative robot (cobot) palletising solutions, work alongside human workers to quickly calculate pallet pattern definitions, and significantly reducing programming time and making it easy for operators to implement changes.

Data-driven change

The reductions in energy usage needed to achieve ambitious net zero targets, however, can rarely be achieved on the factory floor alone. Smart use strategies that harness the internet of things (IoT) and artificial intelligence (AI) models can help factories analyse their real-time production line data usage data, to identify efficiencies. This helps manufacturers to implement solutions, which may be as simpleas adjusting the settings on inverters.

Robotics can also drive greater energy efficiency in palletising, where the rise of e-commerce and the trend towards high mix low volume (HMLV) manufacturing has made mixed pallets more common

When such a system was used to continuously monitor the air and operational situations in a factory clean room, for example, it found hours in which production and quality were unaffected when the air conditioning was turned off. It meant the team was able to implement a new policy on air conditioning use, significantly reducing energy consumption and the related costs.

Adapting to a sustainable future

While there are some areas of manufacturing where small adaptations can lead to big savings, reaching net zero will also require fundamental changes in areas such as the collection and analysis of production data, and the movement of goods around the factory floor.

- Excerpts from an opinion piece by Sam Tilley, Regional General Manager (UK, Ireland & Nordics), OMRON

Autonomous mobile robots: OMROM

RS Components OMRON

Digital Digest

Designers’ are Better-off With Fiverr’s

HP Indigo and Fiverr Collaborate to Bring Digital Print Closer to millions of Expert Freelancers and Designers Worldwide HP Indigo, the market leader in digital Print, and Fiverr International Ltd. (NYSE: FVRR), the company that is changing how the world works together, today announced a collaboration that makes Digital print more accessible to Fiverr’s millions of users.

PSPs who are part of HP Indigo’s global user community can now offer their services on Fiverr’s new “solution marketplace”, allowing Fiverr’s global network of freelancers and designers to extend their services to a full solution that includes printing.

“As a market leader, recognised by brands globally for setting the standard in digital print and with an install base of over 8,000 presses around the world, we commit to continuously drive the digital transformation and support our customers to expand the demand for digital print services”, says Noam Zilbershtain, VP & General Manager, HP Indigo & Scitex.

“This collaboration offers Fiverr’s freelance talent and businesses a seamless, end-to-end experience that spans from initial design concepts to the final printed product. This comprehensive suite of services ensures that all aspects of the design and print process are covered, from A to Z”, says Gali Arnon, Chief Business Officer at Fiverr.

Under the umbrella of HP Indigo, every Fiverr user can now find the printing collaborators they need for their business. With the world’s largest digital print user base, HP Indigo plans to expand this collaboration by incorporating more print services and applications through its extensive print network.

The global reach of HP Indigo users complements Fiverr’s worldwide presence. Fiverr, with its hundreds of thousands of freelancers offering a wide array of services, can now extend these to include printing solutions.

This marks the start of a collaboration between HP and Fiverr, beginning with select HP Indigo PSPs featured on Fiverr’s new solution marketplace. This will serve millions of users, focusing on Fiverr’s designers’ community.

HP Inc. (NYSE: HPQ) is a global technology leader and creator of solutions that enable people to bring their ideas to life and connect to the things that matter most. Operating in more than 170 countries, HP delivers a wide range of innovative and sustainable devices, services and subscriptions for personal computing, printing, 3D printing, hybrid work, gaming, and more.

For more information on HP visit: http://www.hp.com

Retail Round-up Where First Impressions Count

Online retail is harnessing the impact of First Impressions. Packaging is more than just a protective casing; it’s a storytelling medium. Online businesses use packaging to communicate their brand’s story, ethos and values. This can be achieved through the use of brands, colours, logos and personalised messages that resonate with the customer.

Shared success

In the age of social media, the unboxing experience has become a shareable event. Customers often share their unboxing experiences online, which can turn packaging into a powerful marketing tool. Creative, aesthetically pleasing packaging is more likely to be photographed and shared on platforms like Instagram, extending the brand’s reach and creating organic marketing opportunities. This phenomenon highlights the importance of designing packaging that is not only functional but also photogenic and in line with the brand’s digital image.

Waitrose 1930’s packaging from their “Memory Store”

“ With customers becoming increasingly discerning about where they spend their money, our ambition is to ensure that our brand refresh will help to make Waitrose feel more relevant ”

Furthermore, personalisation in packaging can significantly enhance the customer’s unboxing experience. Simple touches like a personalised note or customised packaging based on customer preferences can make the experience feel exclusive and tailored. A level of personalisation shows customers they are valued, which can lead to increased customer satisfaction and loyalty.

The Rise Of Sustainable Packaging

One of the most significant trends in online retail packaging is the shift towards sustainability. As consumer awareness about environmental issues grows, there is an increasing demand for eco-friendly packaging solutions. This trend is seeing online businesses adopt biodegradable, compostable, or recyclable materials for their packaging. The use of plant-based inks, limited designs that reduce material use, and packaging that can be repurposed are other examples of sustainable practices gaining popularity. These initiatives not only cater to the environmentally conscious consumer but also help brands project a responsible and forward-thinking image.

Smart Packaging

Smart packaging is another innovative trend transforming the online retail experience. This involves integrating technology into packaging to enhance functionality and user engagement. Examples include QR codes that provide additional product information, augmented reality features that allow customers to interact with the product in a virtual space and NFC (Near Field Communication) tags for authentication and tracking. Such technology not only adds value to the customer experience but also provides brands with valuable data and insights.

Integrating Product Information

In the absence of physical browsing, conveying product information through packaging becomes essential. Clear, concise information about the product, its usage, and any additional details can be integrated into the packaging design.

This approach not only informs the customer but also adds to the trustworthiness and transparency of the brand. Welldesigned, informative packaging can enhance the customer’s understanding and appreciation of the product, leading to better satisfaction and repeat purchases.

Endorsing the need for creating ‘first impression’s packaging, Waitrose developed a special, new positioning, campaign to promote its new concept. ‘Food to Feel Good About’ which has exceeded all expectations since its launch. The upmarket grocer launched the campaign with a TV advert outlining Waitrose’ need “to go further in our ambition improve first impressions and to give animals a better life and farmers a better future, and to look after people and the planet”.

The campaign was developed internally using data from the Waitrose customer strategy, which features insights from more than 4,000 target shoppers and staff. “With customers becoming increasingly discerning about where they spend their money, our ambition is to ensure that our brand refresh will help to make Waitrose feel more relevant and more compelling for our customers.” said a Waitrose spokesperson.

Celebrate! with Paper Packaging!

As we enter the vibrant summer festive season, food vendors are seeking packaging that balances practicality and sustainability, whilst enhancing the overall customer experience. Imagine running a bustling mobile food stall with hungry visitors eagerly waiting to indulge in your delicious offerings. What if the right packaging could make all the difference in serving them quickly and efficiently?

The summer season transforms our foodservice setups, with mobile café’s and temporary coffee stalls becoming prevalent. However, these dynamic environments have limited storage space, requiring packaging that is efficient, easy to use, and that supports effective presentation. Enter Colpac, a UK based designer and manufacturer that specialises in the development of certified, food safe paperboard food packaging.

With recycling and composting facilities becoming increasingly available at festivals and events, and consumers being more sustainably conscious than ever before, paperboard packaging provides flexible solutions for recycling and composting.

Colpac’s Multi-food pots are ideal for fast-paced foodservice operations. They nest neatly in storage and their wide apertures allow for quick, mess-free filling, helping to reduce waiting times and keep long queues moving smoothly. They also offer an alternative to plastic pots in the marketplace, providing packaging made from renewable sources and that can be recycled within a more efficient waste stream. Colpac’s multifood pots are manufactured from FSC® certified paperboard and are recyclable in line with the UK’s On Pack Recycling Label (OPRL) guidelines.

The company moved the manufacture of its paperboard multifood pots to the UK in 2022, reducing the carbon footprint of finished goods and securing shorter lead times for UK and European customers. Following product success, the company has also recently expanded the range to add a 950ml option, meaning it now includes five sizes from 470ml to 1300ml, so offers plenty of choice to serve festival favourites.

The hustle and bustle of events means speed and ease of use are paramount. Colpac’s two compartment boxes are designed to meet these needs.

Secure closures and grease-resistant coatings help your culinary creations to be handed over without spills, maintaining the integrity and presentation of your food from truck to hand. They also have an integral divider, making them ideal for combining main dishes and sides within one pack, whilst keeping them separated, enhancing the dining experience for your customers, and streamlining your packaging.

Ready to elevate your festival foodservice? Discover more about Colpac’s paperboard packaging to help you sell more food while meeting the demands of the summer season.

For more information visit: www.colpacpackaging.com

Multi-food pots

Two compartment boxes

Elevate your branding and stand out on shelf

Compared to alternative packaging solutions, consumers find the D-PAK carton unique and innovative. With a 360-degree communication space, your product will stand out on the shelf, elevating your brand.

*Kantar quantitative test and face to face interviews December 2023.

PapairWrap, Paboco, Leipa

Bye old Bubble Wrap

A recent partnership between packaging company Leipa UK and start-up PapairWrap brought one of the most innovative packaging solutions we’ve seen so far this year. In an industry first, the pair introduced bubble wrap made from 100% paper in a bid to combat the traditional plastic packaging dilema.

Manufacturer PapairWrap believes this product will significantly contribute to their vision of a world without unwanted plastic packaging waste. The new protective material has already turned heads throughout the packaging world, winning the top innovation prize at this year’s Packaging Innovations and Empack exhibition in Birmingham

From Plastic to Paper

Plastic has long been the favoured material for packaging manufacturers across the globe. However, in recent years there has been a distinctive change within the packaging landscape. We have witnessed a growing movement against plastic packaging over the last number of years. Global governments have been making crucial changes to plastic packaging regulations, with the United Nations (UN) treaty on plastic pollution to be agreed later this year.

Consumer attitudes towards the environmental impact of plastic packaging have also dramatically changed, with 80% of consumers acknowledging our collective responsibility in reducing the use of single-use plastics.

The implementation of plastic packaging policies and heightened environmental awareness has intensified the demand on organisations to establish greater sustainable practises. Packaging plays a crucial part in global plastic waste; therefore, many brands have emphasised the importance of transitioning from plastic solutions in favour of paper packaging alternatives.

Various global brands are taking the lead in the movement away from plastic packaging, introducing innovative packaging makeups that are driving the shift from plastic to paper packaging materials.

“ Referred to as the ‘Next Gen Paper Bottle’ Paboco has launched full-scale production of its paper-based bottle product at its manufacturing headquarters in Denmark ”

Paper-Based Bottles

Referred to as the ‘Next Gen Paper Bottle’, Paboco has launched full-scale production of its paper-based bottle product at its manufacturing headquarters in Denmark. Aiming to produce over 20 million bottles by the end of 2025, Paboco are looking to work alongside eco-conscious brands who are set on making a sustainable change to their packaging solutions. Produced using 85% paper, the groundbreaking bottle is durable, splashresistant and appropriate for recycling.

UK supermarket giants Aldi have also released a breakthrough paper bottle solution. Made from 94% recycled paperboard and lined with a food-grade protective layer, Aldi have launched paper wine bottles for its own-brand Shiraz and Sauvignon Blanc South African wines. Aldi has identified the desire for sustainable products from their consumers and have developed a paper bottle which will reduce their carbon footprint to the equivalent of driving around the planet 5.8 times.

Sustainably Packaged Snacks

Top brands throughout the food and drinks industry are also becoming more eco-conscious, as many swap plastic for paper in their packaging strategies.

The iconic cylindrical tube of Pringles crisps has recently experienced drastic changes, moving away from the steelbased tube which has been around since the 1960s. The potato snack brand has abolished the former material used for the tube, which is now made from recycled paper, meaning consumers can recycle the paper packaging tube once finished.

- Excerpts from a posting by Leipa UK on 23/04/2024

Courtesy Aldi UK

Image Courtesy Paboco

Bioplastics leading the field

By Dominy Jones

In recent years,

the bioplastics

revolution has been gaining momentum, promising a sustainable alternative to conventional plastics that have long plagued our environment. As global awareness of environmental issues grows, so does the demand for eco-friendly materials, and bioplastics are at the forefront of this movement.

What are Bioplastics?

Bioplastics are derived from renewable biological sources such as corn starch, sugarcane, and even algae, as opposed to traditional plastics made from petroleum. These innovative materials can be biodegradable, compostable, or both, significantly reducing the environmental impact associated with plastic waste. The main types of bioplastics include polylactic acid (PLA), polyhydroxyalkanoates (PHA), and starch blends, each offering unique properties and applications.

Environmental Benefits

The primary advantage of bioplastics is their potential to reduce carbon footprint. The production process of bioplastics typically emits fewer greenhouse gases compared to conventional plastics. Moreover, as they decompose more quickly and safely, bioplastics help alleviate the burden on landfills and reduce pollution in oceans and other natural habitats. This makes bioplastics a vital component in the fight against climate change and environmental degradation.

Industry Adoption and Innovation

The shift towards bioplastics is being embraced by various industries, from packaging and agriculture to automotive and electronics. Major corporations like Coca-Cola and Nestlé have started incorporating bioplastic bottles and packaging into their product lines, showcasing a commitment to sustainability. The fashion industry, too, is exploring bioplastics for textiles and accessories, highlighting the material’s versatility.

“ Researchers are developing new blends and composites to enhance the properties of bioplastics, making them more durable and suitable for a broader range of applications ”

Gaia Biomaterials compostable material Biodolomer can replace fossil plastic in everything from drinking cups to grocery bags

Gaia Biomaterials is unique as the company’s homecompostable material, Biodolomer, is based on limestone, one of the most commonly available minerals on earth. Biodolomer can replace fossil plastic in everything from drinking cups to grocery bags. It is fully compostable with a minimal carbon footprint and does not result in any micro-plastics during the composting process.

“There are very few limits,” says Peter Stenström, CEO. Our material can be used in various production techniques, including film blowing, bottle blowing, thermoforming, injection, and extrusion coating, with no changes in machinery. This makes it easy for brand owners to drastically reduce their CO2 emissions and reduce the waste mountain problem. Today, Gaia has a production capacity that can be scaled up to 50,000 tons/year within the existing structure.

“The need for plastic replacement is recognized globally, and we are witnessing tremendous interest in our offerings. Responding to the high demand from brand owners, we are currently expanding our network of commercial agents worldwide.”

Innovations in bioplastics are also driving the revolution forward. Researchers are developing new blends and composites to enhance the properties of bioplastics, making them more durable, heat-resistant, and suitable for a broader range of applications.

Bioproducts Group, a biomaterial innovation company

Nordic Bioproducts Group, a biomaterial innovation company and developer of pioneering AaltoCell Technology, has entered a strategic MOU with PTT MCC Biochem Company Limited, headquartered in Bangkok, Thailand.

The project will prioritize the development of ‘home compostable’ materials targeting single-use products such as coffee capsules, cutlery, containers, plates, and mugs –enlarging the growing markets.

Nordic

“ most coffee capsules are produced from aluminium, which is not compostable, ensuring their compostability is key to making the whole industry more environmentally friendly ”

The coffee capsule market is expected to grow to USD 11.9 billion by 2032, with Asia Pacific being the largest market for coffee capsules in 2023, followed by Western Europe. However, most capsules are produced from aluminium, which can be recycled but is not compostable. As single-use packages more often end up in nature than recycling centres, ensuring their compostability is key to making the whole industry more environmentally friendly.

“The collaboration represents a significant step forward in the green transition through innovative, high- performance, and environmentally friendly alternatives to traditional plastics. Bringing high-quality and competitive solutions to the market is key to making alternatives to plastic attractive and scalable,” says Olli Kähkönen, CEO and co-founder of Nordic Bioproducts.

Poly lactic acid (PLA) bioplastics are gaining significant traction in China as the country continues to prioritize sustainability and environmental stewardship. With increasing awareness of environmental challenges and the need for eco-friendly solutions, PLA’s renewable, industrially compostable, and lowcarbon footprint properties make it a compelling alternative to traditional fossil-based plastics.

“The growing relevance of PLA bioplastics in China reflects a broader shift towards sustainable consumption and production practices,” says Hao Ding, Global Marketing Director at TotalEnergies Corbion. “PLA’s eco-friendly attributes align with China’s sustainability goals, making it a preferred choice for industries and consumers alike.”

Challenges and the Road Ahead

Despite their benefits, bioplastics face several challenges. One significant issue is the cost of production, which is currently higher than that of traditional plastics. However, as technology advances and economies of scale are achieved, these costs are expected to decrease. Additionally, the infrastructure for composting and recycling bioplastics is still underdeveloped in many regions, necessitating further investment and policy support.

Another challenge is the potential competition with food resources, as some bioplastics are made from edible crops. This raises concerns about the impact on food prices and availability. Researchers are exploring non-food biomass and waste materials as alternative sources for bioplastic production to address this issue.

Conclusion

The bioplastics revolution represents a significant step towards a more sustainable and environmentally friendly future. While challenges remain, continued innovation and industry adoption hold promise for overcoming these hurdles. As consumers, businesses, and governments increasingly prioritise sustainability, bioplastics are poised to play a crucial role in reducing our reliance on fossil fuels and mitigating the environmental impact of plastic waste. The journey towards a greener future is well underway, and bioplastics are leading the charge.

Innovia to launch extended portfolio of recycled content films

Extended portfolio reflects growing demand for films with recycled content to comply with upcoming PPWR regulations within the EU. The new additions include mechanically and advanced recycled content for BOPP films as well as a Prevented Ocean Plastics option to drive circularity.

Innovia Films, a leading material science pioneer and major producer of BOPP films, has announced the launch of an extension to their range of sustainable films, that have been marketed under the Encore brand name.

“One big cornerstone of the Packaging and Packaging Waste Regulation (PPWR) is the integration of a certain percentage of recycled post-consumer content into plastic packaging. This regulation will have a huge impact on how brands are going to design their packaging and the motivation for this regulation is to reduce the per capita quantity of packaging”, says Simon Huber, Managing Director Innovia Europe.

“Flexible packaging, being lightweight and highly resource efficient, can help reduce the total amount of packaging being used and has a much lower CO2 footprint regarding transportation than many rigid alternatives. Innovia is working with the whole value chain in initiatives like CEFLEX (Circular Economy for Flexible Packaging) to increase the recycling of this flexible packaging back into film. The inclusion of recycled content in new films is top of the list for much of the industry – moving from a linear to a more circular system” explains Steve Langstaff, Head of Recycling at Innovia Films.

Film Recyclability - A Report from APR

New Film Star

A major report from APR announces the firstever modelling of scaled FFP Film recycling that includes design, collection-methods and costs.

The new APR Report Studies Pyrolysis as Possible Complement to Mechanical Recycling for Plastic Film and Flexible Packaging (FFP) The Association of Plastic Recyclers (APR) released today a comprehensive report that models the potential of pyrolysis technologies, as a complement to mechanical recycling, to recycle FFP back into plastic resins to be remanufactured into new plastic products.

Prepared by Eunomia Research & Consulting, “How to Scale the Recycling of Flexible Film Packaging: Modelling Pyrolysis’ Role in Collection, Quantity and Costs of a Comprehensive Solution,” details the opportunities for increased FFP recovery volumes, the logistics and costs necessary to get materials to pyrolysis and other re-processor markets, as well as the package design and policy necessary for change..

“This report represents an important next step in the conversation because it links together the changes needed to create a scalable recovery system for residential FFP,” said APR President & CEO, Steve Alexander. “Chemical recycling technologies, including pyrolysis, are one step within a larger recycling system.

Like mechanical recycling, chemical recycling technologies will not scale without changes in package design, substantial investments in collection and sortation infrastructure, stronger consumer participation, and improved economic levers for manufacturers to encourage more use of recycled content.

FFP packaging is a significant and growing packaging segment and includes a broad array of snack packaging, pouches, bread bags and many other applications. While the challenges and potential opportunities for recycling FFP packaging have been discussed for nearly a decade, the industry is now at an inflection point for these materials. Several countries and U.S. states are setting recycling goals for FFP, and numerous brand companies have publicly committed to producing only reusable, recyclable, or compostable packaging by 2030. While over 1.1 billion pounds of polyethylene film were recovered for recycling in 2021 (Stina Inc), the vast majority of flexible film packaging is not recycled.

New Policy Focus

“We intentionally focused this report on FFP packaging used by consumers in the home as opposed to more homogeneous post-commercial streams,” said Greg Janson, CEO of Granite Peak Plastics and Co-chair of the APR Chemical Recycling Research Working Group.” We know this to be a policy focus and a very challenging packaging stream to collect, sort, and recycle due to its light weight, diversity of materials, sizes, and formats. We wanted to fully understand the logistics and costs of pyrolysis’ potential role in recovery.”

The APR supports responsible chemical recycling technologies that complement mechanical recycling by converting postconsumer plastics back into recycled resins for new plastic products. This report was designed to better understand the potential complementary nature of re-processing technologies and how they might fit within a scalable recovery system for residential FFP.

The findings illustrate that scaling the recycling of residential FFP back into recycled plastic is feasible but will require comprehensive and unparalleled supply chain coordination and investment.

The full report is available in the APR Library of resources, which includes other reports, studies, white papers, videos, and more. For further details contact: Kara Pochiro, VP of Communications & Public Affairs: Kara@PlasticsRecycling.org

BOPE packaging for our future sustainability

 Multi-layer mono-structures

 Superior film properties

 Dedicated line concepts

 Perfect match with the circular economy

The big picture Coveris

Feedback to SPN’s searching questions are provided by Martin Berlekamp, Group Sustainability Director at Coveris.

How ‘sustainability-aware’ would you say your company is and what recent measures have you taken to improve your overall contribution to the circular economy?

Coveris’ commitment to sustainability is an integral part of the company’s strategy. Through our No Waste vision, we are driving the circular economy for packaging. With our ReCover business, we are investing heavily in recycling infrastructure and capabilities to provide closed-loop solutions for plastics and paper packaging.

In relation to sustainability, what would you say have been your most important milestones?

The most important milestones include offering sustainable product alternatives in our portfolio, such as easy recyclable monomaterial solutions in paper and plastics or products with a high percentage of recyclate content. A further milestone is using 75% of carbon-neutral electricity in our plants so far and expanding our recycling capacity in our ReCover facilities. However, this is just the beginning. Within our strategy, we have a clear target to develop the circular economy and will continue this path by further investing in recycling technology.

In your opinion what have been the most significant developments in terms of recycling and bio-degradable packaging?

The Circular Economy Action Plan (CEAP) of Europe can serve as a guide. However, Coveris has long been aware of its responsibility and has taken proactive measures accordingly. We provide recyclable packaging solutions and using recyclates into our products wherever possible, considering both technical feasibility and legislative requirements. While biodegradable packaging presents a challenge to the recycling stream, it’s essential to consider natural-based materials to protect goods without hindering recycling streams. At Coveris, we remain open to such solutions but evaluate the total environmental benefit. Alternatives like raw materials from second generation bio-based feed stocks (like waste from other industries) appear promising as they reduce carbon dioxide impact and do not disrupt waste streams. It is important to remember that packaging contributes only a minor percentage to the overall carbon dioxide impact compared to packed goods.

What do you consider to be the most promising market opportunities for your company at this time?

With the shift towards the circular economy, changing customer perception and evolving regulations, the most promising opportunities lie in a holistic approach to packaging solutions -which we defined in our No Waste vision, avoiding waste in all its forms by protecting the goods, manufacturing sustainable packaging with lowest carbon footprint and avoiding waste in production, embracing responsibility for the circular economy evolution.

What are the key drivers for change in your industry sector and how much is the on-going pressure for greater sustainability and recycling affecting your productivity?

The entire industry is undergoing a fundamental transformation due to the growing sustainability requirements. We are supporting our customers in making the right decisions. We provide workshops to inform them on the total cost of ownership and the benefits of Coveris’ sustainable solutions.

Martin Berlekamp, Coveris

As we are keen to understand more about the latest trends shaping the packaging industry in your sector, what do you consider to be the most significant recent developments?

Nowadays it is impossible to ignore the effects of climate change. Therefore, sustainability is essential and close to everyone’s heart. Regulatory bodies also recognise its significance, with regulations being proposed by individuals. Now, as consumers, we must take action and decide at the point of sale which type of packaging we support. This decision may require more time and information, but as consumers, we bear the responsibility to drive fundamental change. The industry is ready.

Can you describe your product portfolio and its sustainability credentials?

Coveris’ product portfolio for consumer goods is made up of both paper and plastic solutions. Our plastics portfolio is mainly based on the manufacture, print and conversion of high-performance polyethylene and polypropylene films. Both polymers are classified as recyclable, and recycling streams and capacities are installed in Europe.

We manufacture primary packaging for packaging-sensitive goods such as food and medical devices, but also secondary packing and technical films, so we use a wide range of raw materials. For technical films and secondary packaging, we already offer films with over 80% recyclates. In the case of contact-sensitive packaging, we are actively exploring options that meet consumer safety and legal requirements.

Are you planning the launch of any new products in the foreseeable future that you can tell us about?

Our entire “Forward Thinking” R&D labs and centres are focussed on developing sustainable packaging solutions, with every new idea and project carefully aligned with sustainability requirements. Within our MonoFlex monomaterial portfolio, our latest developments include MonoFlex Fibre, a paper-based range of flexible packaging that delivers high shelf-impact and allows recycling in existing paper streams. With this innovation, we achieved the same level of protection and barrier properties as with mixed materials, while ensuring full recyclability within the existing paper cycle.

For more information visit: https://www.coveris.com/

EREMAGROUP

TO FULL RECYCLING SOLUTIONS

We have everything covered, regardless of whether your new project is for polyolefin or PET recycling. Each of the individual process steps is perfectly tuned to ensure that what you get in the end, is what you were expecting from the beginning. The right sorting and washing equipment, the most suitable water treatment, the perfect extruder. Get the best results from EREMA Group‘s decades of experience in plastics recycling.

Eco-Fee Modulation Interzero

Eco-fee modulation is a concept that introduces packaging fees based on the sustainability, e.g. recyclability of packaging. In accordance with extended producer responsibility, license fees are levied in stages: Through sustainable packaging design, companies can benefit from reduced fees and thus save costs. Packaging that does not fulfil the requirements of eco-modulation on the other hand, is taxed at a higher rate than environment-friendly packaging.

Interzero Recycling Alliance has already carried out successful pilot projects as part of eco-fee modulation. We analyse the packaging for the respective target markets in order to check the recyclability of the packaging. The certification can then be communicated in a legally compliant manner. In this context, it is also assessed whether there are opportunities for cost savings in relevant countries or whether the company is already classified in the best possible licence group.

The evaluation shows which countries have implemented eco-fee modulation already. In addition, Interzero Recycling Alliance provides information on whether your packaging is already entitled to benefit from eco-modulation and how high the financial savings are. As a customer, you will also receive optimisation tips if the packaging does not yet have the design to benefit from reduced Eco-Fees. In addition to Eco-Fee modulation, you can also receive information regarding the recyclability of your packaging.

How recycling-friendly is your packaging?

Consumers expect transparency – and policymakers have also been tightening standards: packaging should create a minimal impact on the environment and be easy to recycle.

Want to know where your packaging stands in terms of recyclability? The “Made for Recycling” seal from Interzero stands for innovative and highly recyclable packaging. By integrating the seal into your packaging design, you signal your commitment to a sustainable circular economy and communicate this effectively.

Our evaluation method: economical, transparent and international approved.

• Neutral standard for evaluating the recyclability of packaging, developed by bifa instistute and tested by Fraunhofer IVV.

• Recyclability assessment

• Laboratory analysis with industrial size NIR-sorting and material analysis

• Reporting and recommendation for even better recyclability

• Certificate of recyclability (2 years valid) and “Made for Recycling Interzero” quality seal

After analysing each of your packaging samples against standar¬dised criteria, our experts provide you with a comprehensive assessment, and support you in defining sustainable and practical strategies for optimisation. This means you are well equipped: both for the legal require¬ments such as the EU packaging regulation (PPWR) or the Ger¬man ZSVR minimum standard, as well as for the requirements of numerous European and global sales markets.

Get in contact with us for more information: made.for.recycling@interzero.de

Downgauging Takes Off!

PURINA is a leading retailer of pet food. In an effort to become more circular the company has significantly reduced the amount of plastics in its packaging by PE downgauging.

Purina told SPN “Plastic is ubiquitous in today’s society. A great amount of plastic is specifically flowing into the packaging industry. However, economic and technical limitations cause most plastic packaging to have a linear and unsustainable life, often characterised by a very short use phase”.

Positive impact

To decrease the use of plastic Purina has made considerable progress in ensuring the use of only a minimum amount of packaging to pack products safely. Purina has opted for downgauging, which means reducing the thickness of the plastic film to reduce the weight of packaging used, establishing the minimum operational thickness. For example, Purina cuts the weight of some of its packaging by downgauging the PE (polyethylene) layer.

This packaging change has already been implemented across its European factories and achieved a positive impact on its overall packaging reduction, allowing Purina to reduce 528.3 tonnes of packaging in total.

Meeting targets

In 2016, as part of the Purina in Society Commitments, the company set a target to avoid the use of 3,000 tonnes of packaging material by 2019 compared to 2015 levels. In 2018, it avoided 787 tonnes of packaging, and in total, since 2015 it has avoided 3,542 tonnes of packaging, meaning that the company has over-delivered on this target by 18%. 52% of the avoided packaging material since 2017 was plastic.

Purina’s efforts to reduce the use of plastics in its packaging doesn’t stop there. Purina is working on eliminating or changing complex combinations of packaging materials, so that all its packaging, including plastics, is recyclable. Purina is also working on incorporating, where possible, recycled plastics in its packaging and investing in research to find sustainable materials that protect pet food in the same manner as plastics.

For more information visit: https://www.purina.co.uk/your-questions-matter/sustainability/

Sustainable Adhesives

Sticking Together

From the desk of Steve Gislam

Finding ways of attaching one thing to another is something that humans have always grappled with. The history of adhesives goes back thousands of years, evolving from simple natural substances to sophisticated synthetic compounds. It’s a journey that reflects human ingenuity in developing materials to bond surfaces together. Here, we’ll take a look at the backstory of adhesives, where we are now, and what developments lay ahead as the packaging sector strives to reach its climate goals.

Ancient bonds

Evidence of adhesive use dates back some 200,000 years, when early humans used tar made from birch bark to attach stone tools to wooden handles. Early adhesives were derived from natural sources such as plant resins, animal glues, and bitumen, and were often heated and applied to surfaces. Ancient Egyptians used animal collagen, beeswax and plant resins in woodwork, pottery and construction. The Greeks and Romans used substances like egg whites and animal blood.

Through the Middle Ages, the knowledge of adhesive formulae was a closely guarded secret by craftsmen, but thus far, adhesives were made of entirely natural materials.

Then came the Industrial Revolution, which brought with it significant advancements in adhesive technology. The invention of rubber-based adhesives in 1845 marked a shift towards more versatile and durable adhesives. Towards the end of the 19th century, adhesives were being manufactured on a larger scale, and the development of synthetic adhesives began.

Development continued throughout the first half of the 20th century, and companies that are still major players in their fields like 3M, Le Page, and Henkel – which its celebrated centenary last year – began establishing themselves. It wasn’t until the post war era when synthetic adhesives really became ubiquitous. Epoxy resins, polyvinyl acetate (PVA), and super glue entered the market, providing strong, fast-curing, and versatile bonding solutions for manufacturers and consumers alike. With their quick setting times, hot melt adhesives were widely adopted by a packaging industry trying to keep up with the rapidly increasing consumer demand.

But of course, it was too good to be true. Not only are synthetic adhesives not biodegradable but they negatively affect air, water, and soil, as well as human health. Their production is energy-intensive, and can release particulates into the air, causing air pollution and respiratory problems. Over time, they began accumulating in landfills, leeching harmful chemicals into the soil and groundwater.

Early in the 21st century, the explosion in environmental awareness among the public changed the game entirely and is proving a driving force in the development of sustainable alternatives to synthetic adhesives. Nascent technologies are aiding in the creation of smart adhesives, with added functionalities such as self-healing properties, conductivity, and responsiveness to stimuli such as light or heat.

“ We live in an era where eco-friendliness is at the forefront of the collective consumer consciousness. There’s an increased pressure on all sectors ”

Sustainable adhesives offer a promising alternative to their petrochemical counterparts. Designed to hit that sweet spot of meeting the rigours and demands of modern packaging while aligning with global sustainability goals, they incorporate renewable resources, minimise greenhouse gas emissions, and enhance biodegradability, all without compromising performance or function.

And they’re a fast-growing market. A 2023 report by Ceresana predicted that the market share for adhesives made, at least in part, from renewable raw materials will rapidly increase, with global revenues tipped to reach some USD 3.8 billion by 2032.

greener adhesives

We live in an era where eco-friendliness is at the forefront of the collective consumer consciousness. There’s an increased pressure on all sectors, including packaging, to develop and adopt more sustainable ways of making things stick together. Adhesive companies are pouring large amounts of time and money into the next generation of their product. But what will they look like? How are they made? What are they made from? Let’s look at some of the latest trends in eco-friendly adhesive technology.

Bio-based adhesives

As the name suggests, bio-based adhesives are derived from living (or once-living) organisms, such as plants, algae, and other natural materials.

Soy-based adhesives, made from soy protein, are increasingly being used for packaging applications for paper and cardboard, labels, laminates. They provide a strong bond while coming with a reduced environmental impact. Some hot melt adhesives incorporate bio-based content such as natural waxes, oils, plant-based polyolefins, and resins. Coming from biological sources, they’re also biodegradable, non-toxic and usually produces fewer emissions during manufacture that their synthetic counterparts.

Water-based adhesives

These adhesives use water as a solvent instead of chemicals and are made using natural polymers such as starch, dextrin or casein. Not only do they release fewer volatile organic compounds into the air, but their overall environmental impact is lower and their production is safer for workers. Water-based adhesives have applications in carton sealing, case and tray erecting and labelling.

The Industrial Revolution brought with it significant advancements in adhesive technology

Microbial and enzyme-based adhesives

Renewable, biodegradable, and with a reduced environmental impact, microbial and enzyme-based adhesives represent an exciting frontier in adhesive technology. They’re made using microbial fermentation, or enzyme catalysis, and thus lever biological processes to create sustainable bonding solutions.

Wash-off adhesives

An exciting new development is wash-off adhesives. Residue from traditional label adhesives can affect the recycling process. Products like Dow’s INVISU 7007 sidestep this issue by enabling clean label separation and higher quality recycling output.

Adhesives made from waste and byproducts

By utilising waste materials or industrial byproducts, these adhesives not only provide a second life to otherwise discarded byproducts but also offer cost-effective, non-toxic, eco-friendly alternatives to traditional adhesives as well as helping develop a circular economy. Industrial byproducts can come from a number of sources. For example, Lignin, which is a byproduct of the paper and pulp industry and is generated during the process of extracting cellulose from wood.

Fittingly, it is particularly suitable for wood adhesives. Plant waste can also be utilised for adhesives. Projects like the Aimplas-supported FUSTARISE Project, is developing ways to find more sustainable solutions to transform plant waste, such as mechanochemistry, and give it a second life in the form of adhesives.

What’s the catch?

As great as all of this sounds, there are, course challenges to the uptake of more sustainable adhesives. They are often more expensive that their synthetic counterparts, because of higher raw material and processing costs.

There may also be additional costs, if existing machinery and other equipment requires modifications. What’s more, matching the performance of conventional adhesives in terms of strength, durability, and versatility can be difficult.

Sealing the deal

Despite the challenges (and costs), it’s important for any business to have a sense of which way the wind is blowing. Right across the packaging sector, we are witnessing significant changes, spurred on by changing consumer attitudes and a new way of thinking about our relationship with the planet. It seems inevitable that this need for sustainability will lead to regulatory changes, making it increasingly harder not to embrace newer technologies.

While costs may be higher now, increased adoption will drive down costs over time. And as the development of new adhesives technologies continues apace, issues related to performance are likely to lessen. While the green movement is taking something of a knock lately, it’s becoming harder to keep our heads in the sand when it comes to climate change. Necessity is the mother of invention, and industry’s tendency towards innovation means new eco-friendly adhesives will continue to be discovered, as the packaging sector strives to reduce its environmental footprint.

Performance-Pooling Proven

How Pooling Reusable Secondary and Tertiary Packaging significantly Reduces Waste. Amid new laws and regulations promoting reuse and discouraging single-use plastics, businesses must explore sustainable and efficient solutions for their supply chains. Reusable secondary and tertiary packaging within a pooling system can significantly reduce waste. It can also support a circular economy, and future-proof operations, making it an essential strategy for sustainability.

The Role of Secondary and Tertiary Packaging in a Circular Economy

Circular economy principles—reuse, recycle, and reduce are essential for reducing waste. While primary packaging and recycling often grab the spotlight, reusable secondary and tertiary packaging solutions are equally vital for creating sustainable, circular supply chains. Durable and multi-use, reusable plastic pooled packaging —such as containers, crates (RPCs), plastic pallets, and bulk bins—replace single-use materials and/or recycling significantly reducing waste and energy use, and enhancing supply chain efficiency.

Reducing Waste with Reusable Packaging and Pooling Solutions

Reusable packaging reduces waste across supply chains in several ways, especially when integrated with efficient pooling solutions. These include:

Promoting Reuse: Reusable containers, crates, and pallets are designed for multiple uses, extending their lifecycle, and reducing the need for constant production and disposal.

Superior Product Protection: Durable and reusable plastic packaging offers better content protection, particularly for food, reducing damage and thus minimising food waste.

Reducing Cardboard Use: Replacing single-use cardboard with reusable plastic alternatives cuts down on cardboard waste across the supply chain, including in fresh produce and food ingredient transportation.

Efficient Pooling Solutions: Pooling further reduces waste by efficiently managing and circulating packaging assets among multiple users, maximising utilisation, and lifespan of the product.

Recyclable plastic assets: 100% of plastic assets are recyclable unlike cardboard which is an important way to reduce waste at the end of the life cycle of the product.

Addressing Legislative Pressures

Regulatory changes are accelerating the shift towards reusable packaging. Legislation such as the EU Packaging and Packing Waste Regulation (PPWR) and Extended Producer Responsibility (EPR) laws focus on single-use plastics, compelling companies to adopt reusable solutions for both sustainability and cost-efficiency. These regulations position reusables at the forefront of waste reduction efforts.

Conclusion

Reducing waste in supply chains requires more than just reducing single-use primary packaging or reliance on recycling. Reusable secondary and tertiary packaging is equally crucial. These durable, multi-use solutions, especially when supported by pooling systems, significantly enhance supply chain efficiency and sustainability. By incorporating reusable plastic packaging, businesses not only meet regulatory requirements but also support a circular economy.

For more information on Tosca and it’s smart and sustainable solutions visit: www.toscaltd.com

“

The functionally well thought-out and timeless design ensures that it is a pleasure to operate and makes it a powerful, sophisticated and elegant machine ”

An ATS banding machine that sets new benchmarks ATS

The successor to the world’s best-selling banding machine combines the best of more than 30 years of mechanical engineering experience with state-of-the-art technology. This makes it the most reliable, user-friendly and sophisticated banding machine with ultrasonic sealing technology we have ever built.

A perfect combination of design and function

The robust banding machine is made exclusively of high-quality materials and components. The functionally well thought-out and timeless design ensures that it is a pleasure to operate and makes it a powerful, sophisticated and elegant machine with a high recognition value.

A Positive user experience

A positive user experience increases productivity by avoiding operator errors, reduces training costs and ensures motivated employees. That’s why we’ve invested heavily in design. From the self-explanatory user interface to the height -adjustable table and effortless band change.

Service and maintenance have never been more efficient

After easy removal of the arch cover and table, all components are conveniently accessible. The clear separation of mechanics and electronics ensures ideal order, structure and overview. Error diagnoses and information for rectification are provided via the HMI.

Prepared for standardized data exchange via IO-Link

Built-in temperature, humidity, G-force and vibration noise sensors will in future provide information on the causes of failures and enable predictive maintenance. The controller is prepared for the connection of intelligent sensors and actuators with IO-Link. For example, for the automatic measurement of products via a light barrier.

Energy-efficient ultrasonic sealing technology

Banding machines with ultrasonic sealing technology are the most powerful, reliable and energy-efficient packaging machines on the market. For example, they consume 98% less energy than shrink wrapping machines. In addition, they achieve the highest cycle rates, work in extremely cold, dusty or humid conditions and ensure consistent weld quality over time. They do not require preheating and do not generate heat during welding that could damage sensitive products.

Customer benefits

• Highly reliable, fast and low-maintenance banding of a wide variety of products.

• Low energy costs and low CO2 emissions thanks to the use of ultrasonic sealing technology

• Operates even in the most challenging environmental conditions

• Minimal training effort for multilingual staff thanks to intuitive, icon-driven user interface

• Ergonomic working with tiltable 5” capacitive touchscreen and easy height adjustment without loss of stability

• New simplified dispenser concept for quick and easy band changes

• Easy troubleshooting with context-sensitive, language-independent on-screen help

• Easy access thanks to large service doors and intelligent design

• Enhanced error cause information on the HMI with integrated temperature, humidity, G-force, and vibration sensors

• Standardized data exchange with existing production lines and connection of intelligent sensors and actuators via IO-Link (IIoT ready)

• Meets EU Machinery Directive 2006/42/EC and C standard EN 415-8 for strapping machines.

TG Pack Solutions

Sustainability in the Plastic Packaging Industry

No doubt the plastic packaging industry is going through transformational chances towards sustainability. This transformation should be seen as a chance not as a threat. TG PACK SOLUTIONS helps the packaging value chain to achieve their sustainability goals.

Dr. Thomas Gröner

We need to look at sustainability holistically and at the same time we have to take in consideration the specific requirements of the individual companies in a flexible way. There is no one-fits-all solution existing.

It is mandatory to evaluate always what activities make sense for a certain company to achieve in the best way concrete, significant and noticeable sustainability improvements.

TG PACK SOLUTIONS recommends to break down the whole sustainability theme for companies producing plastic packaging into 9 Areas of Sustainability Activities: materials, products, production and company foot print, people, customer, targets and KPIs, communication, regulation and external collaboration.

Within these 9 Areas of Sustainability Activities you can work out specifically for each and every single company custom-fit and relevant actions to improve the sustainability. Below you find five examples:

1. Increasing the use of recycled plastic can be a great lever for one company to increase sustainability. In contrast for another company this can be irrelevant because of constrains in terms of technology or restrictions from product which will be packed (e.g. food contact packaging).

2. For an electricity intense operation, the use of CO2 neutral electricity (green electricity) can significantly reduce the CO2 foot print of the company, in many cases at reasonable oncost. Such switch can be done in steps if needed.

3. Customer oriented sustainability certification (e.g. EcoVadis) is as important as to follow the relevant regulatory changes for example new supply chain laws in various countries like Germany or Switzerland.

4. From a sustainability strategy we can derive goals to be monitored by KPIs. This brings clarity and transparency.

5. External and internal communication has always a very important role to play in the sustainability arena. “Walk the talk and talk the walk”. Sustainability communication is not only essential towards our markets and customers but as well in terms of employer branding: the attractivity of an employer for existing and potential new employees. Attracting the best people is of growing concern in our industry.

These are just five examples from a big bunch of possibilities to improve the sustainability of a plastic packaging company. Every sustainability program needs to be tailormade for the individual company concerned thus relevant and impactful. The transformation of our industry towards sustainability is essential I would even say this transformation is essential for the survival of the industry as such and of each and every single company. The potential solutions are many, they have to be actionable and have to make a difference. TG PACK SOLUTIONS supports plastic packaging producer on this journey.

Dr. Thomas Gröner founded in 2021 TG PACK SOLUTIONS an independent result-focused consultancy to the packaging value chain the area of Sustainability, Innovation and Business Development with a special expertise in flexible packaging. Dr. Thomas Gröner builds on his more than 30 years industry experience: lately as Director R&D and Sustainability at RKW SE, until 2018 he served as Head of R&D and Innovation for the global activities in flexible packaging of Mondi and before he had various European positions in packaging R&D with Nestlé the world largest food company.

“

new awareness among consumers has drove a concerted push among FMCG and packaging businesses to develop and adopt ecofriendly solutions ”

Speeding up the greening of FMCG packaging

From the desk of Steve Gislam

Fast-paced, high-volume and with a quick turnover, the FMCG sector is facing several sustainability challenges as it strives to clean up its act environmentally. Its large and rapid nature means FMCG is one of the sectors facing the most public scrutiny, and with good reason. As one of the largest industries in the world, it comes with a sizeable environmental impact and is a major contributor to greenhouse gas emissions, plastic waste and water pollution.

Whilst the necessity of packaging food and other goods has long been a part of human life, the story of the FMCG sector really begins with the Industrial Revolution and the advent of mass production. As the availability of consumer goods increased, what they were packaged in became more important, and the packaging sector adapted accordingly.

The Gamechanger

The classic go-to packaging back then was paper or cardboard for dry foods and household items, and glass for drinks and other liquids. But the invention of the tin can in 1810 proved a true gamechanger. It revolutionised food packaging by allowing for longer shelf life and the safer storage and transport of perishable food items. The development and widespread adoption of plastics like polyethylene, polypropylene, and polyethylene terephthalate – better known as PET – completely changed the rules of the game for the FMCG sector.

“ The number of businesses developing biodegradable and compostable packaging has skyrocketed ”

The 1950s saw a rise in demand for convenience foods, which required packaging that was easy to open, reseal and store. As refrigerators became a common feature of every kitchen in more and more homes, the demand for convenient packaging increased with it. Then, in the 1960s, Tetra Pak upped the ante again with the introduction of aseptic packaging, allowing liquids to be stored at room temperature. This led to greatly extended shelf lives for many products, but it also greatly increased the use of plastics

During those years, recycling points became more common in towns and cities everywhere, especially for glass, as public consciousness regarding global warming began to grow. But it took until the mid-2010s, when the effects of manmade climate change became harder to ignore, for the tide to truly turn.

The greening of FMCG

This new awareness among consumers drove a concerted push among FMCG and packaging businesses to develop and adopt ecofriendly solutions. Indeed, a study of UK-based packaging experts conducted by biodegradable plastics company Aquapak, showed that the vast majority, some 92%, of those responsible for the packaging of FMCG brands were planning to stop using traditional plastics in their consumer packaging altogether.

Material innovation has played a huge role in this. The number of businesses developing biodegradable and compostable packaging has skyrocketed. These use plant-based plastics that decompose naturally, sometimes even adding nutrients back into the earth as they do so.

Tetra Pak’s aseptic packaging, allowing liquids to be stored at room temperature

“ smart packaging is the pivotal innovation for sustainability in FMCG, making products greener and more in line with shifting demands ”

There has also been a pivot towards recycled and recyclable content as a way of reducing the need for virgin materials, minimising waste and working towards a circular economy.

Package design teams are also increasingly opting for a more minimalist approach. For example, reducing the amount of material used in packaging decreases waste and resource consumption.

Nonetheless, that same Aquapak study also found that, while the commitment was there, most experts said it was happening far too slowly, with some 27% saying they expected the move away from plastic packaging in the FMCG sector to happen by 2027, 35% by 2028 and 28% by 2029.

Getting Smarter

One of the most exciting developments in the FMCG packaging sector is how the integration of smart technology into traditional packaging can significantly enhance sustainability. For example, using QR codes on product labels, it’s possible to track expiry dates, monitor the freshness of perishable items and find real-time information on their condition. These could include indicators that change colour based on freshness to help consumers use products before they go bad.

RFID Tags in FMCG packaging can also help sort materials more accurately during the recycling process. This ensures that different types of materials are correctly identified and processed, improving recycling rates.

RFID tags and sensors can track products throughout the supply chain. Optimised logistics use real-time data to improve inventory management, reduce overproduction, and minimise waste.

Smart packaging can also be designed to work with supermarket refill stations, by tracking and rewarding consumers for reusing packaging. Apps can provide notifications and incentives for refilling, supporting a circular economy.

The future of FMCG

Through this combination of material innovation and rising consumer environmental awareness, the Fast-Moving Consumer Goods market is already being transformed beyond recognition. Overall though, it is smart packaging that is the pivotal innovation for sustainability in FMCG, making products greener and more in line with shifting demands.

Even so, there is still a long way to go. FMCG is one of the world’s largest sectors and such enormous volumes of products create a large environmental footprint. If businesses embrace the power of smart technology, it’s a win for the brand, a win for consumers, and a win for our planet. And who doesn’t want that?

QR codes are enhancing packaging

Colpac

Navigating the Changing Sustainability Landscape

In today’s bustling marketplace, where consumers are championing environmental change, it is even more important to navigate the ever-changing landscape. This could be as simple as avoiding greenwashing claims around packaging, or as complex as understanding recycling legislation across the world.

Standing out is paramount. This is especially true in the food industry where packaging provenance and sustainability are often equal to that of the food within, given that packaging can be the first interaction that a consumer has with a brand on-shelf.

Partner to Leverage Expertise

Colpac has been leading the drive for sustainability in the packaging sector from the introduction of its first compostable lines in the 1990s and has kept pace with legislative change since. Company representatives are also active members of industry, technical, and stakeholder groups and advocate for policy and regulation change to support environmental and ethical goals across the food packaging industry.

“ Colpac has an established supplier network, meaning its customers have access to a plethora of materials, often those which are new to the market ”

Colpac’s recyclable, UK manufactured multi-food pots.

Colpac’s customers can access in-depth knowledge through our experts in sustainability, materials, and quality assurance. The team functions as an extension of the customer’s, striving to deliver solutions that represent a brand’s sustainability goals, create on-shelf impact, increase value perception, and drive customers’ sales.

Material Selection & Choice

Central to packaging success is the meticulous selection of materials. Sustainability, durability, and compliance with food safety standards are non-negotiable material characteristics. Colpac delivers added value consultancy on material sourcing and performance, by leveraging sustainably sourced, highquality materials and conducting rigorous due diligence and testing protocols, helping brands to elevate product quality, and therefore value, whilst aligning with consumer preferences.

Colpac has an established supplier network, meaning its customers have access to a plethora of materials, often those which are new to the market. For example, Colpac’s recent project for Strathmore Foods, a leading ready meal manufacturer in the UK, involved working closely with the board manufacturer to supply material for testing and production. Sustainability was paramount and the board needed to be composted and recycled, as well as certified food safe for use in oven, freezer, microwave, and hot-hold environments.

Educating Consumers to Reduce Packaging Impact

Disposable food packaging has attracted a huge amount of media attention in recent years and has therefore become an area of focus for consumers. According to Pro Carton, 90% of shoppers would like information about the environmental credentials of packaging. Colpac is a UK based food packaging manufacturer, so uses the UK’s On-Pack Recycling Label (OPRL) guidelines as the basis of its recycling information, and the EN13432 European standard for its composting information.

To enable products to reach the correct waste streams, consumers need to be able to access information about what to do with packaging after use. Colpac’s approach to this is to print stock products with Quick Response (QR) codes and specific recycling instructions, which can be dynamically updated as legislation continues to evolve. The information is available for national recycling schemes in the UK, France, and Italy to date and guidance is displayed in local languages to inform end users of how to best dispose of packaging.

Sustainability packaging legislation is complicated and constantly changing. If you’re looking for a partner to develop packaging which considers sustainability through design, materials, and sourcing, Colpac can help you create sustainable solutions that function throughout the supply chain.

To find out more about Colpac’s sustainability initiatives visit: https://colpacpackaging.com/sustainable-food-packaging/

Colpac’s bespoke hot food packaging developed for Strathmore Foods.

Selection of Colpac packaging with QR codes pointing consumers to specific sustainability credentials.

Gualapack

The Success Story of Gualapack’s Mono-material Pouches

Gualapack, headquartered in Alessandria, Italy, is the global leader in premade spouted pouches. Pursuing a vision of “Growing sustainably, competing with the best” has led the company to develop a ground-breaking solution for sustainable, flexible packaging: recyclable mono-material pouches certified suitable for a vast range of food and non-food products, offering the performance and convenience consumers crave, while also enabling eco-friendly behaviours. Find out how Gualapack leveraged its unique excellence to innovate the market with this ideal packaging solution.

Flexible packaging has witnessed substantial growth in the past years for both food and non-food categories.

This clearly ties in with the market’s intensifying preferences for convenient and sustainable solutions: pouches are great for eco-conscious consumers looking for ways to reduce packaging waste, as well as for busy parents who need on-the -go baby food or healthy fruit purees in an easy-to-use format.

Despite this popularity, the conventional multi-layer laminate traditionally posed challenges for recyclability – driving the need for innovation.

Gualapack pioneers mono-material flexible packaging

In 2020, Gualapack launched Pouch5®: the first-ever monomaterial pouch made entirely of PP, targeting the baby food segment – and providing a previously unavailable recyclable solution. Initial success led to rapid expansion, with the innovative pouch gaining traction across 15 countries to date.

Having tackled the most stringent food contact regulations since the first batch, Gualapack swiftly proved the product is suitable not only for baby food but also for dairy products, spreads, supplements, beverages, detergents, cosmetics, and various other categories.

The process behind a revolutionary product

Gualapack’s achievement stems from its unique combination of in-house expertise, strategic partnerships, and environmental awareness.

1. Vertical integration. By controlling the entire production process – from material formulation to pouch making to the manufacture of filling lines for clients – Gualapack was able to ensure quality and consistency throughout the development of its innovative solution. The company’s team of experts maintained control over every aspect, guaranteeing seamless coordination and optimisation across the value chain.

2. Strong partnerships. Long-standing relationships with forward-thinking suppliers and clients were key to co-develop and thoroughly test a bespoke PP-based material. The shared goal was to achieve recyclability while upholding oxygen, vapour, and light barrier characteristics, ensuring integrity and shelf life to the benefit of end consumers.

3. Sustainability culture. Gualapack’s commitment to recyclability fits into a broader environmental awareness that motivates the company to constantly lower its impact, taking an active role in the evolution of guidelines and regulations in the packaging industry. From this position, it was able to collaborate with major stakeholders like TOMRA and RecyClass to validate the recyclability of mono-material pouches in existing rigid PP streams.

The new standard for sustainability

Pouch5’s client portfolio has quickly grown from 24 brands in 2021, to 41 in 2022, to 63 in 2024 and counting. In addition to its market success, Gualapack’s mono-material solution garnered recognition winning the 2021 Best Packaging award in Italy and “Highly Commended Flexible Plastic Pack” at the UK Packaging Awards in 2022.

But the most outstanding results achieved with this innovation are tangible environmental benefits: Pouch5 reduces the carbon footprint about 30% compared to traditional pouches in cradle-to-grave assessments, lowering emissions and promoting circularity.

Now, Gualapack continues to invest significant resources in developing other mono-material pouches and laminates designed specifically for recyclability, aligning with circular economy guidelines by CEFLEX and RecyClass and implementing rigorous life-cycle assessments (LCA) within an advanced eco-design process. As the company continues to prioritise recyclability, its mono-material pouches serve as a beacon for sustainable packaging innovation, inspiring positive change across the supply chain and in people’s daily lives – under the brand’s environmental motto, “Less is more”.

For more information on Gualapack and it’s recyclable pouches visit: https://gualapack.com/

SPN June 2024

SUSTAINABLE PACKAGING NEWS

Sustainability in FMCG

AI = Supply Chain

SmartCycle®

Sustainable Label Films

Samples

Welcome to

Supply-chain Sleuths

AI driving supply chain efficiency

Coca-Cola turning to Microsoft’s AI services

20-20 Vision

Reducing the food value-chain footprint

Packaging’s role

Optimised flexibility

New Centre of Excellence for “Bright Minds”

Catalyst Approach

Ambitious Sustainability Goals

Intelligent energy management for a net zero world

Materials handling and GHG emissions

Data-driven change

Adapting to a sustainable future

Digital Digest

Designers’ are Better-off With Fiverr’s

Retail Round-up Where First Impressions Count

Shared success

The Rise Of Sustainable Packaging

Smart Packaging

Integrating Product Information

Celebrate! with Paper Packaging!

Elevate your branding and stand out on shelf

PapairWrap, Paboco, Leipa

Bye old Bubble Wrap

From Plastic to Paper

Paper-Based Bottles

Sustainably Packaged Snacks

Bioplastics leading the field

What are Bioplastics?

Environmental Benefits

Industry Adoption and Innovation

Challenges and the Road Ahead

Conclusion

Innovia to launch extended portfolio of recycled content films

More recyced content options for converters and brand owners

Film Recyclability - A Report from APR

New Film Star

New Policy Focus

BOPE packaging for our future sustainability

The big picture Coveris

Feedback to SPN’s searching questions are provided by Martin Berlekamp, Group Sustainability Director at Coveris.

EREMAGROUP

TO FULL RECYCLING SOLUTIONS

Eco-Fee Modulation Interzero

How recycling-friendly is your packaging?

Our evaluation method: economical, transparent and international approved.

Downgauging Takes Off!

Positive impact

Meeting targets

Sustainable Adhesives

Sticking Together

Ancient bonds

greener adhesives

Bio-based adhesives

Water-based adhesives

Microbial and enzyme-based adhesives

Wash-off adhesives

Adhesives made from waste and byproducts

What’s the catch?

Sealing the deal

Performance-Pooling Proven

The Role of Secondary and Tertiary Packaging in a Circular Economy

Reducing Waste with Reusable Packaging and Pooling Solutions

Addressing Legislative Pressures

Conclusion

An ATS banding machine that sets new benchmarks ATS

A perfect combination of design and function

A Positive user experience

Service and maintenance have never been more efficient

Prepared for standardized data exchange via IO-Link

Energy-efficient ultrasonic sealing technology