Issue 21:3 - September 2021
SUSTAINABLE
PACKAGING NEWS
Taking the lead in sustainability
Circular Economy Looking at the research that is contributing to achieving a truly circular global economy
Compostable / Bio-degradable
Bio-compostable and bio-degradable innovations
Consumer Impact Downgauging
Oceans of sustainability
Coca-Cola signs up with its global implementation partner for the ‘Ocean Cleanup’ project. SPN looks at environmental initiatives and recyclable packaging
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WELCOME TO SPN MAGAZINE
Welcome to
SUSTAINABLE
PACKAGING NEWS
Dear Readers, A warm welcome once again to our latest issue of Sustainable Packaging News. It is our biggest issue yet and packed with the latest developments within our industry. In addition, it offers many valuable guides and suggestions on upcoming legislation and how to optimise packaging circularity and sustainability.
September 2021 Issue 21:3 - September 2021
SUSTAINABLE
PACKAGING NEWS
Taking the lead in sustainability
Circular Economy Looking at the research that is contributing to achieving a truly circular global economy
Compostable / Bio-degradable
A great deal has happened since the last magazine was published and it is good to know that thankfully we are at last seeing a general easing of the Covid 19 restrictions and a return to a more normal way of life. It is also interesting to note that despite all the trials and tribulations of the past year, it appears that the packaging industry has stood up particularly well to the global Pandemic. In fact, the ‘bounce-back’ in the consumer sector has seen a marked shift in product demand, as well as for more recyclable packaging. Furthermore, there is a greater consumer awareness today of how much the industry is doing to meet the many challenges ahead. Our latest issue features a broad palette of content. It ranges from Tackling Carbon Emissions and the Protection of Products during Transit, to Downgauging and Beverage Packaging. What’s more, it includes a reminder of the government’s latest tax on plastic packaging, which is coming up next year. So whatever your involvement in the industry, there is something here to help you to build upon your success, and we hope that you find the content both interesting and useful in your day-to-day endeavours to save our planet! Sincerely,
Philip Yorke ( Editor )
Bio-compostable and bio-degradable innovations
Consumer Impact Downgauging
Oceans of sustainability
Coca-Cola signs up with its global implementation partner for the ‘Ocean Cleanup’ project. SPN looks at environmental initiatives and recyclable packaging
Director Editor Writer Designer
Kevin Gambrill Philip Yorke Emma Jane Batey Dom Thorby
linkedin.com/company/ sustainable-packaging-news/
news_packaging
spnews.com SUSTAINABLE PACKAGING NEWS
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CONTENTS
Contents TOPICS
BEVERAGES 11 New HP technology 12 Oceans of sustainability PROTECTION DURING TRANSPORTATION 18 Damaged goods? Damaged reputation CIRCULAR ECONOMY 20 Re-inventing the circle 22 Graphic Packaging 26 Sustainability is good for buisness 32 TetraPak investment programme 34 CCT
REGULAR FEATURES SUPPLY-CHAIN SLEUTHS 6 Laser marking 20-20 VISION 8 Shuttle Service - Shuttlepac DIGITAL DIGEST 10 New report on digital printing
COMPOSTABLE/BIO-DEGRADABLE 46 Bio-Fed 47 Enhancing compostable packaging 48 Crunch time for crisps
6
Downgauging 53 Downgauging without compromise TACKLING CARBON EMISSIONS 54 Cartonboard Vs carbon emissions 55 Cutting down carbon emissions recycled materials 58 Putting the ‘R’ in PET 60 Safety in numbers consumer impact 64 Tilda impact report 68 Zenten - plumbing magic
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Issue 1 Sep 2020
CONTENTS
11
46 18
54
20
SUSTAINABLE PACKAGING NEWS
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SUPPLY-CHAIN SLEUTHS
Supply-chain Sleuths
Laser-sharp advantages Laser marking is already a growth industry in the world of packaging. It has the capability to mark items as diverse as automotive and aerospace parts as well as the common carton. That’s enough to make laser-marking a major contender in the future when it comes to marking packaging.. Sustainability and traceability are two of the most important considerations in supply chain logistics today. Whilst both are typically looked at as big-picture subjects, their implementation and success are all about the smallest of details, especially in packaging. For example, if you want to permanently mark an individual item without consuming a consumable. Then that’s the purest form of traceability and sustainability. Bar-coded labels utilise two consumables, namely label stock and ink. However, these can be removed from packaging if someone’s got the time and a reason to do it. There’s also the matter of common label abrasion during shipment. So, you’ve then got two strikes against optimum traceability and sustainability. Ink jet coding data directly on an item ranging from a carton to a bottle of water, somewhat changes the consumable equation. The label may be gone, but the ink is still a consumable, and it too can be removed with a simple alcohol wipe.
By contrast, there are no consumables in laser marking. No inks. No labels. In fact, even the carbon dioxide consumable originally needed for laser coding is now history. What’s more, the carbon dioxide lasers used today are completely sealed and have a life of at least five to seven years. That’s about as small a consumable footprint as you can have, which is quite impressive.
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“ the carbon dioxide lasers used today are completely sealed and have a life of at least five to seven years ” Better yet, laser markings are entirely permanent. They are engraved in the surface of the item. And that is a huge bonus for laser marking, especially for automotive and aerospace parts. Additionally, DataMatrix bar codes are commonly laser-engraved into those parts ensuring permanent identifiers on elements in industries with increasingly stringent traceability requirements. When it comes to the common carton, it at an earlier stage of development. Whilst it’s easy to laser mark a carton, it is not very legible unless it appears in a high-contrast box or field. While the trajectory of laser is not as clear as the markings it makes, the technology is certainly making advances. Consumer and legislative demands for increased traceability and sustainability are sure to give laser-marking a major boost going forward. Extracts from an article by courtesy of David Holliday, director of product marketing at ID Technology.
SUPPLY-CHAIN SLEUTHS
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.
SUSTAINABLE PACKAGING NEWS
7
20-20 Vision
20-20 Vision
Shuttle service
The Covid 19 pandemic affected every aspect of people’s lives as well as every manufacturing company in the world. It is easy in retrospect to see how things could have been done better. However at Shuttlepac which has been on the front line serving the NHS, among many others in the healthcare industry, the company’s efforts to develop and utilise more recyclable plastic has paid dividends for both healthcare trusts and patients alike.
Over the last two years, the demand for recyclable plastic has grown beyond all expectations. The Covid pandemic has also added to this increase in global demand. However, Shutlepac has been optimising its recyclable capabilities and is now one of industry leaders in this field. It is estimated that since the 1950s, humans have produced over 8.3 billion tons of plastic. It has only been brought to the attention of the public in more recent years, by documentaries (such as Our Planet with David Attenborough) or by activists such as Greta Thunberg. The British Government has launched the 25 Year Environment Plan which has pledged to eliminate all avoidable plastic waste by 2042. This will include the abolishment of plastic straws, carrier bags and food packaging.
Plastic in Healthcare However, much of the single use plastic in healthcare is seemingly unavoidable, with a whopping 25% of the waste generated by hospitals being plastic. The use of plastic gloves and masks in hospitals are integral to protect healthcare workers from disease. Plastic is an extremely desirable material for hospitals and other healthcare environments due to it being low cost, very easily processed, very lightweight and able to be sterilised very easily. Plastic can even be modified to have a bacteria-resistant coating to help protect workers.
8 SUSTAINABLE PACKAGING NEWS
“ much of the single use plastic in healthcare is seemingly unavoidable, with a whopping 25% of the waste generated by hospitals being plastic ”
20-20 Vision
“ home testing kits are now being rolled out across the nation ”
While it is clear nobody can argue that safely disposing of hazardous PPE or biohazardous samples is an essential use of plastic, only 15% of healthcare waste is classed as “hazardous”. This title covers waste that could be a source of infection or is radioactive or toxic. The other 85% of medical waste is not dissimilar from the plastic waste generated at home, which is where the reduction could come from. In your typical operating theatre, there will be vast quantities of “blue wrap” used to place sterile equipment on or inside, which could easily be replaced by a sterilisable container. Surgeons also often use small resealable disposable plastic bags to keep their sterilised equipment inside, and it has been suggested this could be replaced by a small tightly woven pouch such as those created by EnviroPouch which was created in 1993 and purchased by Barbara Knight in 2001. Plastic gloves are another example, where in some cases are used unnecessarily. There was a time, as stated by the Sustainable Development Unit for England’s National Health Service, when nurses at London’s Great Ormond Street hospital realised that healthcare professionals were choosing to use non-surgical gloves instead of washing their hands, when performing tasks such as moving beds or bathing babies. When nurses started to remind staff that the gloves were not intended for these purposes, glove usage went down. The hospital was able to cut its use of plastic gloves, saving 21 tonnes of plastic and £90,000 ($120,000) as a result.There are many uses for which, in healthcare, that plastic is currently the best option at our disposal at present. Hospitals can never be zero plastic waste due to biohazardous waste material, but there are certainly still ways to reduce this.
Help at hand Working with industry experts, we shuttlepac has identified the many pain-points plaguing the industry (including the massive plastic wastage) with conventional 95kPa biohazard bags. The reduction of plastic, as well as producing the highest quality product, is at the forefront of every single one of Shutlepacs designs. Its UN3373 compliant biohazard transport solution – the ShuttlePouch™ - is the item of choice when it comes to reducing plastic wastage and providing secure secondary storage for biological material. The 73% reduction in plastic usage means that, when it comes to home-test kits, swapping to the ShuttlePouch™ would have a noticeably positive environmental impact. Shuttlepac told SPN, “The biohazard transport packaging market is dominated by unnecessarily large plastic packaging. We are the first in the industry to prioritise the reduction in plastic usage, and our overall environmental impact. Now is the time to move into the modern age by employing the state-of-the-art shuttlepac packaging solutions for biohazard transport. We at shuttlepac are championing the reduction of plastic in biological sample secondary packaging. Did you know that the ShuttlePouch™ offers on average a 73% reduction in plastic when compared to our direct competitors? Could you imagine shopping for a few groceries and packing it in FOUR plastic bags instead of one? Yet this is normalised practice within the healthcare industry”
Home-Testing Kits With the effects of the pandemic still in full swing, and home testing kits are now being rolled out across the nation, it is estimated that the UK is currently testing over 580, 000 people per day and over 4 million people per week. With this much single use plastic needing to be disposed of, and some of it incinerated seemingly the only way to cut back on this is to make the plastic packaging as small as possible within the regulatory guidelines, which the majority of test providers are not currently doing.
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DIGITAL DIGEST
Digital Digest
New Report shows market share boost
The Global digital printing packaging market share boosted to 13.9% CAGR through 2027. The data presented in business intelligence literature on ‘global digital printing packaging market’ enables readers to understand the growth patterns of the industry over 2021-2027 by acquainting them with growth stimulants, remunerative prospects, and bottlenecks. According to credible sources, global digital printing packaging market size was valued at USD 19.44 billion in 2020 and is reckoned to record a compound annual growth rate of 13.9% during 2021-2027 to accumulate USD 48.35 billion by the end of analysis timeframe. Moreover, the document incorporates Porter’s Five Force Model, investment adoption model, and PEST analysis, in consort with opinions from subject matter experts to assist in better decision-making. Lastly, it assesses the competitive arena and renders a detailed outline of winning strategies adopted by the major players to help stakeholders improve their returns. Demand of flexible and sustainable packaging, huge investments for research and development activities, along with cost-effectiveness nature of digital printing packaging are catalysing the industry expansion. Notably, this type of packaging is aesthetic and is adept for different surfaces. Despite the positive outlook, volatility in raw material prices due to high demand from suppliers, and strict policies & regulations are hampering the industry growth to some extent. Despite the positive outlook, volatility in raw material prices due to high demand from suppliers, and strict policies & regulations are hampering the industry growth to some extent.
Outlining market segmentations In terms of technology, worldwide digital printing packaging industry space is bifurcated into electrophotography, and inkjet technology, wherein, the former segment holds a major market share currently, owing to quality and flexibility offered by this technology.
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Based on packaging type, the industry vertical is classified into flexible packaging, corrugated packaging, folding packaging, and labels. With respect to format, the industry sphere is fragmented into variable data printing, large format colour printing, full-colour printing, and others. Speaking of end-user terrain, the marketplace is divided into healthcare, electronics, personal care, food & beverages, and others. Among these, the food & beverages segment is slated to capture a substantial market share in the ensuing years.
Elaborating regional spectrum Expert analysts claim that Asia Pacific is expected to generate revenue for the market over the analysis timeframe, with India and China at the forefront, owing to presence of huge number of players, rising e-retail sales, and preference for attractive packaging for food & beverage items. On the other hand, North America industry is slated to grow momentously through 2027, attributed to easy availability of raw material, and low-cost packaging. To view this report in detail visit: www.marketstudyreport.com/ reports/global-digital-printing-packaging-market-size-research
Beverages
New HP technology benefits beverages Print service providers and consumers increasingly demand better packaging experiences with less environmental impact. This is a growing trend that many brands are capitalising on to increase their product’s appeal and drive sales. The beverage industry has been one of the driving forces in instigating positive change, diligently working to reduce environmental impact through initiatives like light weighting, life cycle assessment tools and the development of flexible, reusable packaging. As packaging consultants, print service providers (PSP) play an important role in the ecosystem of the brands responding to this new demand. In developing sustainable technology solutions, HP is enabling PSPs to take greater responsibility for the environment and their products. HP supports beverage brands help them to choose the best possible sustainable packaging option without compromising on speed or quality of output. Additionally, HP, supplies the digital printing solutions frequently used by the beverage labelling and packaging industry, known as HP Indigo and HP PageWide. HP Indigo develops presses and inks that enable label printers and converters to comply with regulations that meet industry standards and environmental credentials. Furthermore, as the demand for recyclable, paper-based packaging grows, the need for innovation has never been more important.
Unlike LED technology, HP PageWide Technology operates without a fuser, reducing heat and noise generated – and producing no ozone. HP PageWide presses also use true water-based inks which enable trusted food-safe printing for both primary and secondary corrugated packaging, requiring no additional barrier. Inks for both HP Indigo and PageWide digital presses are free of UV-reactive chemistries and can comply with even the most stringent global food safety regulations, including Nestlé guidance and Swiss Ordinance. Coupled with its cartridge recycling programmes and energy efficient design, HP helps customers to achieve their sustainability goals and support others in their environmental goals along the supply chain.
When printing labels, there’s a big difference between printing and printing with HP Indigo, especially when it comes to sustainability. Decades of innovation and investment by HP Indigo have led to some of the most sustainable packaging solutions on the market. HP Indigo presses are manufactured using renewable energy, plant energy reductions, waste-management and offsetting the remaining CO2 emission, meaning they are certified carbon neutral. These presses also come equipped with technologies that reduce wastage by eliminating print media waste, plates, cylinders, and other elements of conventional printing. On the corrugated side, HP PageWide technology is making waves with converters who utilise the technology for innovative solutions that allow wine and beverage industry customers to adapt to new models built on sustainability.
“ innovation and investment by HP Indigo have led to some of the most sustainable packaging solutions on the market ”
SUSTAINABLE PACKAGING NEWS
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BEVERAGES
The Coca-Cola Company and The Ocean Cleanup are teaming up behind a clear objective: to stem the tide of marine waste by intercepting plastic debris from rivers around the world.
Oceans of Sustainability Coca-Cola signs up with its Global Implementation Partner for the ‘Ocean Cleanup’ project The partnership, which brings together Coca-Cola’s scale and global network with The Ocean Cleanup’s technology and data-driven solutions, will implement cleanup systems, including the Dutch nonprofit’s solar-powered Interceptor, in 15 rivers by the end of 2022.
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Two Interceptors included in this partnership have already been installed by The Ocean Cleanup in Santo Domingo, the Dominican Republic and Can Tho, Vietnam. These initial deployments lay the groundwork for the organization’s goal to expand the project over the next five years
Make life easier! Easy to handle
■
Easy to store
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PAPER PACKAGING SPONSORED
Easy to recycle
For more information contact us at: Daphne.Deledicq@vpkgroup.com or www.blueboxpartners.eu Sustainable Packaging News half-page Horiz 182mm x 116mm V5.indd 1
06/08/2021 14:59
The result development and research ECOGRIP is the result of extensive development and structural research. The concept allows carrying multiple bottles. It provides a 100% biodegradable packaging that can be adapted to fit any type of bottle on the market.
Your Sustainable Partner Blue Box Partners is a paper and packaging producer pan-European alliance. Together with Klingele Paper and Packaging Group, VPK, Hinojosa and Cart-One, we deliver local solutions to global problems. We work with brands to develop sustainable packaging solutions for the long term. Our latest innovative solution is ECOGRIP.
Of course, the impact on the supply chain of any alternative to shrink wrap needs to be customised. Any concept needs to be easy to transport, easy to handle and easy to store to meet demand. Please get in touch to find out how we can help and assist you with your sustainable packaging requirements. Please contact BBP Chief Innovation Officer Daphné Deledicq for more information: Daphne.Deledicq@vpkgroup.com
A corrugated cardboard alternative to plastic shrink wrap Sustainable packaging is an important issue for our planet, especially when it comes to single-use plastics (SUP) that are not biodegradable. While industry continues to improve recycling rates for plastic bottles and containers, an important part of shrink-wrap falls into the category of single-use plastic. More and more, governments, environmental groups and consumers are demanding solutions around sustainable biodegradable packaging.
SUSTAINABLE PACKAGING NEWS
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BEVERAGES
BEVERAGES
“ Among the waste we collect with our cleanup systems, we find many plastic bottles including Coca-Cola packaging, so I applaud them for being the first in the industry to join our mission”
Plastic-free oceans “The Ocean Cleanup’s mission is to rid the oceans of plastic,” said Boyan Slat, Founder and CEO, The Ocean Cleanup. “With 1,000 rivers emitting nearly 80% of river-carried plastic into oceans, this massive problem grows by the day, which is why we are always looking to accelerate our progress. Among the waste we collect with our cleanup systems, we find many plastic bottles, including Coca-Cola packaging, so I applaud them for being the first in the industry to join our mission, as part of their wider actions to make a positive impact on worldwide plastic pollution. Our clear intent is to take our learnings from this partnership, which has the potential to evolve in the future, and continue to scale rapidly. That’s why I believe this is good news for our oceans.” Unveiled in 2019, the Interceptor is the first scalable solution to collect plastic from rivers – the arteries that carry plastic waste from land to sea. Waste flowing with the river current is guided by a barrier towards the opening of the Interceptor. Thanks to the vessel’s catamaran design, the water flow path is optimized to pass through the system, carrying plastic with the current onto a conveyor belt and delivering the waste to a shuttle that automatically distributes it across six dumpsters before returning to shore for recycling. “At Coca-Cola, we have teams on the ground who will support the deployment of new Interceptors in rivers around the world, as well as the processing and recycling of the waste collected,” said Brian Smith, president and chief operating officer, The Coca-Cola Company.
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“Working together, we believe we can have real impact. That’s exciting: it’s something we know our employees in every corner of the world will get behind, by helping to support the local implementation work and as ambassadors for the wider mission.” Coca-Cola will work with The Ocean Cleanup to integrate Interceptors into existing or emerging programs wherever possible. Local teams will work with waste management coalitions to sort and eventually, where possible, turn captured PET plastic bottles into new bottles.
“ Our collaboration will focus on scaling up solutions that prevent plastic waste from entering the oceans ” “Our collaboration will focus on scaling up solutions that prevent plastic waste from entering the oceans, effectively turning off the tap in the world’s most polluting rivers,” said Ben Jordan, senior director, environmental policy, The Coca-Cola Company. “We will leverage our global network of government, community and industry partners to ensure plastic waste collected is processed and recycled in support of a circular economy and never returns to the water. In each market, we will bring system coalitions and networks to the table to make an even greater impact.” It is anticipated that Coca Cola’s commitment to clean up our oceans will be emulated by many other flagship Beverage companies worldwide.
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DON ’ T
WA STE
RESOURCES
L I G H T W E I G H T PAC K AG E S MAKE A DIFFERENCE Ecolean’s approach to packaging is light - to the benefit of both consumers and the environment. We are a global producer of lightweight packaging solutions for liquid food, for chilled and ambient distribution. We reduce your impact on the environment with convenient, innovative and eye-catching packages, by using less resources from the start. Don’t waste resources – join our lightweight approach! www.ecolean.com 16 SUSTAINABLE PACKAGING NEWS
ECOLEAN
Ecolean now sources 100% renewable electricity globally By switching its production plants in Pakistan and China to use green electricity, global packaging producer Ecolean is now sourcing 100 percent renewable electricity globally. Completing the shift to only purchase renewable electricity amounts to a 95 percent reduction of its Scope 2* carbon emissions, compared to Ecolean’s base year of 2018 – one of the key highlights from the Ecolean Sustainability Report 2020. Renewable energy in all production sites globally “We have worked hard on many levels to meet our commitment to use 100 percent renewable electricity for all our production plants by 2030. This target was actually met in 2020 by signing renewable energy agreements for our production sites in Pakistan and China,” says Anna Palminger, Sustainability Director at Ecolean Group. Ecolean’s packages are 50-60% lighter than other types of liquid food packaging, which reduces environmental impact throughout the package’s lifecycle. Less raw materials used means energy and resource savings in production as well as lighter transportation. Most of the energy Ecolean uses is consumed in the production and manufacturing operations and by sourcing 100 percent renewable electricity, Ecolean decreases the environmental impact from its production even further.
Reducing climate impact by 95 percent “If we compare our carbon emission levels from 2020 with data from our base year 2018, we save over 3,400 tonnes CO2-eq by sourcing 100 percent renewable electricity, which amounts to a 95 percent reduction in total in our Scope 2 emissions. This shows our dedication when it comes to doing everything we can to reduce the lifecycle impact of our products. Additionally, by sourcing renewable electricity for all our production sites, we can both reduce our climate impact, while helping to drive the demand for more renewable energy in society,” says Palminger. Ecolean also increased the proportion of total renewable energy used in its operations from 81 percent in 2019 to 96 percent and is now working to replace the remaining non-renewable energy used in power aggregates.
About Ecolean Ecolean develops and manufactures innovative packaging systems for the beverage, dairy and liquid food industry. Ecolean’s modern lightweight packaging solutions and resource-efficient filling lines offer both customer and consumer convenience and environmental responsibility. Ecolean is a global company with its headquarters in Sweden. Established in 1996, the company has commercial activities in over 30 countries, with China, Pakistan, Russia and Europe being its largest markets. Ecolean has 500 employees. *Scope 2 refers to emissions from the consumption of purchased electricity
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Protection during Transportation
Damaged goods? Damaged reputation! Perhaps the single biggest threat to a packaging business is that of transit damage. It can also be amongst one of the most significant on-costs. In fact, in addition to the cost of returns and replacements, it can have an extremely negative impact on a customers’ satisfaction level, as well as on the reputation of the business involved. Damage in transit can also lead to poor brand perception, and eventually can limit a businesses’ potential for repeat sales and improved customer loyalty. The true costs of not preventing transit damage can be significant. Whilst other factors come in to play, such as the quality of couriers and the distance items must travel, having to write-off even a small percentage of the products being shipped can cost thousands of pounds. However, this can sometimes be even more costly where expensive, high quality items are concerned. In fact, damage often goes far beyond just an individual packaging company’s reputation and that of its client. For example, when we consider consumer packaged goods, damage during transit can lead directly to a reduction of on-shelf availability and can also equate to a serious loss of sales. Damage caused to items during shipping not only can incur a significant monetary cost with the returns and replacements, but also can create a negative perception amongst your customers. Besides this, everyone knows the frustration of receiving damaged goods. This is especially acute when they are critical to your business or operations. Add this to the admin associated with returning items and the costs of dealing with this and it can very quickly lead to unhappy clients.
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Happy customers tend to be loyal customers who spend more and will recommend you to their colleagues and friends. Customers that frequently receive damaged items won’t be inclined to continue to use your services, or at least, decide not to offer you any additional business. Therefore the impact on your business and its’ potential growth can be severe.
Protection during Transportation
Protective packaging performance SPN looked at the GWP Group’s operations, which is a leading specialist in packaging transportation. The company often works with businesses that are experiencing package protection problems. However, by analysing the product and the type of damage in detail, and applying their unrivalled experience and knowledge of transit packaging design, they provide cost-effective answers with considerable success In addition, GWP’s solutions are not only engineered to offer the optimal level of protection for a given product but can also engineer-out additional costs. The GWP Group told SPN: “In many cases, using less of the right material is both cost effective and more efficient in terms of protection, than using more of the wrong material”.
Cause and effect Whilst damage to items in transit can occur in a number of ways, there are three scenarios which are most common across most industrial market sectors. Firstly, and perhaps the most observed, is that of prolonged vibration or sudden impact during shipping. Depending on the fragility of the product and type of packaging used, this can either occur suddenly, causing breakage, or from prolonged or repeat handling during transportation leading to fatigue failure. With the average e-commerce order having around 10 touch points prior to delivery, it is essential that packaging can withstand the rigours of a chosen courier network.
Also, a fairly common contributor is damage resulting from poor pallet or load stability. This can be caused in transit by a vehicle cornering and breaking, or by stacking packaging too high, thus resulting in crushing or “bursting”. Finally, and often overlooked, is damage caused to surfaces by abrasion. This can be through excessive vibration and surface contact between the product and its packaging, or even by product touching product, which typically affects printed, polished or painted surfaces.
A ready remedy The GWP Group also said that by working alongside them, companies can take advantage of a wide range of technologies and software that will calculate the exact performance of any packaging that requires transportation. Businesses can benefit from proven strategies and a team of experienced designers that specialise in eliminating transit damage to your items. Ranging from how boxes can be safely stacked, to safe drop-heights and vibration, the use of specialist software or appropriate testing as required enables GWP to create not only the perfect structural design, but also select the optimal material to eradicate any damage.
Example of cost savings achievable The infographic below highlights just how costly transit damage can be – significantly outweighing any cost savings from under-specifying your packaging.
Damage Prevention Example usage / cost calculations Box Box Box Box
Value Value Value Value
Transit Transit Transit Transit
Damage Damage Damage Damage
Returns Returns Returns Returns
(standard box) (standard box) (standard box) (standard box)
(item value - TV) (item value - TV) (item value - TV) (item value - TV)
(no. items delivered) (no. items delivered) (no. items delivered) (no. items delivered)
(% damaged in transit) (% damaged in transit) (% damaged in transit) (% damaged in transit)
(total no. items returned) (total no. items returned) (total no. items returned) (total no. items returned)
£1.00 each £1.00 each £1.00 each £1.00 each
£500 £500 £500 £500
10,000 10,000 10,000 10,000
1% 1% 1% 1%
100 100 100 100
Box Box Box Box
Value Value Value Value
Transit Transit Transit Transit
Damage Damage Damage Damage
Returns Returns Returns Returns
(custom engineered packaging) (custom engineered packaging) (custom engineered packaging) (custom engineered packaging)
(item value - TV) (item value - TV) (item value - TV) (item value - TV)
(no. items delivered) (no. items delivered) (no. items delivered) (no. items delivered)
(% damaged in transit) (% damaged in transit) (% damaged in transit) (% damaged in transit)
(total no. items returned) (total no. items returned) (total no. items returned) (total no. items returned)
£1.75 each £1.75 each £1.75 each £1.75 each
£500 £500 £500 £500
10,000 10,000 10,000 10,000
0.5% 0.5% 0.5% 0.5%
50 50 50 50
+ 75% + 75% + 75% + 75%
NA NA NA NA
NA NA NA NA
50% 50% 50% 50%
50% 50% 50% 50%
Calculations Calculations Calculations Calculations Total packaging cost Total packaging cost returns cost Total packaging cost returns cost Total cost Total packaging returns cost Overall TOTAL Total returns cost Overall TOTAL
Overall TOTAL Overall TOTAL
Calculations Calculations Calculations Calculations Total packaging cost packaging cost Total returns cost Total packaging cost returns cost Total packaging cost Total returns cost Overall TOTAL Total returns cost Overall TOTAL
Overall TOTAL Overall TOTAL
29% 29% 29% 29%
£10,000 £10,000 £50,000 £10,000 £50,000 £10,000 £50,000 £60,000 £50,000 £60,000
£60,000 £60,000
£17,500 £17,500 £25,000 £17,500 £25,000 £17,500 £25,000 £42,500 £25,000 £42,500
£42,500 £42,500
Cost Saving Cost Saving Cost Saving Cost Saving
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CIRCULAR ECONOMY
Re-inventing the circle The Circular economy debate grows daily and it appears that everyone has their own take on what is important and where the future lies. SPN takes a broad look at what is trending and how we can all benefit from the vast range of research and analysis that is contributing to achieving a truly circular global economy. Philip Yorke reports.
Among the companies working diligently to transform today’s plastic recycling systems is Greenback Recycling Technologies, where today the buzzword is ‘System Thinking’. This refers to a situation when a holistic approach is implemented to deal with the plastic waste crisis. It moves away from individual point technology that might solve the plastic recycling problem in isolation, to one that focuses on working in synergy with different technologies. The goal is the same: transforming the plastic recycling system. Holistic solutions are a proven way that will integrate technologies within local waste systems that are already in place thereby providing complete system thinking rather than silo’d ineffective solutions.
“ Holistic solutions are a proven way that will integrate technologies within local waste systems that are already in place ” 20 SUSTAINABLE PACKAGING NEWS
CIRCULAR ECONOMY
New circularity platform One of the latest models embracing this concept is the Greenback Circularity Platform, which has been developed by Greenback Recycling Technologies. The company’s Circularity Platform improves on current audit-based methods to certify proof of material provenance and value. It manages this by using a combination of artificial intelligence and IoT gathered evidence, all backed up on Blockchain to provide additional security. This evidence includes camera images, weigh scale data, smart contracts, and advanced analysis of waste types, including AI recognition. One of the solutions Greenback is implementing today in supporting the recycling of post-consumer plastic waste involves waste pickers sifting through plastic items and then moving these items onto the recycling technology installed literally at the landfill site. One of the novel recycling technologies used by Greenback is microwave induced-pyrolysis. This technology was developed via Enval’s proprietary pyrolysis solution for low-density packaging waste. Pyrolysis recycling technology works by enabling a thermochemical decomposition of organic material at elevated temperatures in the absence of oxygen. It is viewed as one of the solutions for hard-to-recycle flexible plastics headed to landfill, as it allows the treatment of mixed, unwashed plastic waste.
When installed at landfill sites, the technology gives the CPG companies total assurance that the pyrolysis oil has come from post-consumer plastic waste. It also enables waste pickers to be reimbursed at source for separating plastic waste materials into the different waste streams. These pyrolysis plants are scalable and quick to commission, which are key factors to consider in the face of growing recycling quotas and as governments around the world implement more environmental regulations to address plastic waste. A single module can process 2.5kt per annum of hard-to-recycle plastic waste and can neatly scale in 2.5kt increments to meet the need of the available local waste stream. By placing distributed recycling plants close to waste sources, it can also assist local economies extract maximum value from their waste. A combination of local collection, sorting and recycling helps to reduce plastic pollution, water usage, resource depletion and CO2 emissions into the bargain. For more information on Greenback Recycling Technologies, please visit www.greenback.earth
The system has fantastic potential for recycling heterogeneous plastic waste that cannot be economically physically separated and classed.
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Graphic evidence collaboration is the key
Ever since 2017, when ‘Blue Planet’ was first aired, public interest in sustainability has grown expeditiously. Today packaging is considered to be one of the biggest contributors to global waste and therefore a concerted transformation towards fully sustainable packaging is vital. SPN looks at the arguments put forward by one of the world’s biggest fibre-based packaging companies on to how to meet the expectations of the world’s consumers. Philip Yorke reports. Dr Elodie Bugincourt Graphic Packaging’s sustainability manager EMEA, told SPN: “Sustainability has become an overused word. Consumers are smart, critical and demanding. They want real action from brands and suppliers when it comes to their practices and the products they offer. It is no longer enough for brands to make sweeping claims. Consumers expect brands and suppliers to substantiate why their products, services and practices are sustainable and what their effect is on the environment. Talking about sustainability and giving substance to claims, however, becomes rather complex given the different attributes considered, perspectives and local situations, and this creates a lot of confusion for consumers”
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A realistic vision As a producer of over a third of America’s fibre-based packaging, and with almost 100 facilities worldwide, Graphic Packaging International (‘Graphic Packaging’) does not take its leadership position lightly. The company plays an increasingly important role as a global industry sustainability ambassador by offering product portfolios which emphasise renewable and recyclable materials. The company’s ultimate goal, is closely aligned with its ‘Vision 2025’. This is designed to enable its customers to do business and consumers to live their lives more sustainable. Achieved by way by delivering responsible packaging solutions that have a positive impact on the world and optimises circularity,”
“ delivering responsible packaging solutions that have a positive impact on the world ” “In order to fulfill that commitment, we understand we cannot work in isolation,” says Bugnicourt. Packaging legislations and regulations in the sector, and associated industries such as the waste recycling chain, vary a lot depending on their geography.
This level of complexity makes it difficult to make impactful change on a global scale when innovating for increased sustainability. For example, there is an 80+ % recycling rate for paper and cartonboard in Europe, according to Eurostat1. However. This is not typical of every continent. “Just because a pack is recyclable doesn’t mean that it’s recycled,” declared Bugnicourt. In its Vision 2025, the company has set out its commitment to advance its sustainability and social responsibility initiatives and to promote stewardship of the Earth’s natural resources throughout its production processes. This includes ambitious goals to reduce greenhouse gas emissions, decrease dependence on fossil fuel-based energy and responsibility utilise water.
CRYOVAC® Brand Recycle-Ready Shrink Bag Sustainability within reach First in the industry to be laboratory-certified with global recyclability protocols, these new materials are 100% compatible with LDPE/RIC4 recycling streams and offer an EVOH barrier for enhanced product protection and performance.
Find out more www.sealedair.com/recycle-ready-bag *Degree of recyclability depends on the specific product configuration or components intended for recycling and the scope and availability of appropriate local recycling facilities. Based on results achieved for Sealed Air deliverables. All facilities and systems are different, so results may vary.
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“Our focus is on continuous innovation in bringing more sustainable solutions in all segments that we service. To do this effectively, the Graphic Packaging approach is to partner with organisations that unite suppliers, brands and retailers throughout the supply chain. This allows us to better understand how innovation around sustainability can be woven throughout the business to drive meaningful change,” added Bugnicourt.
Global and European forums Graphic Packaging does this on a global stage, through membership of organisations such as the Ellen MacArthur Foundation, the world’s leading circular economy network, which enables collaboration with like-minded businesses, academia, policymakers and institutions to drive systemic change. Feeding into its collaborative innovation on a European level is the company’s work with the Confederation of European Paper Industries (CEPI) and the 4Evergreen Alliance, a forum to engage and connect industry members from across the fibre-based packaging value chain. “What’s exciting about all these partnerships is that it gives each organisation involved, a profound understanding of how to shape new product development in a way that’s not only advancing sustainability and social responsibility initiatives in their particular field, but is also more likely to work in reality across the entire value chain. Thus ultimately, meeting similar ambitious sustainability aspirations across the globe. Any gains we make are amplified through our collaborative efforts, taking us closer to achieving cohesive global circularity at a much greater and more effective rate.”
“ Any gains we make are amplified through our collaborative efforts, taking us closer to achieving cohesive global circularity at a much greater and more effective rate ” Utilising collaborative knowledge Clearly SPN’s take-away from this latest contribution from Graphic Packaging is that any packaging business today can offer functional, convenient and environmentally sound packaging solutions. However, by taking a collaborative approach to research, development and innovation, and backed by the cumulative knowledge of leading global businesses and organisations in the industry, it is possi9ble to make a major difference and to lead the way in defining realistic solutions for a circular future on a global scale. For more information on Graphic Packaging’s sustainable solutions, please visit graphicpkg.com.
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Why Sustainability is good for your business At a recent virtual conference event, Allie Schwertner, Sustainability leader at Rockwell Automation, made a strong case as to why Sustainability is good for your business “Leaders should look at efficiency and sustainability as mutually beneficial goals,” said Allie Schwertner, sustainability and energy leader at Rockwell Automation. “Improving the efficiency of operations will reduce waste, which improves the sustainability of processes. This introduces cost benefits, which can then be reinvested in future projects.”
Schwertner spoke as moderator for a keynote session on “Sustainability: From Vision to Impact,” at the ROKLive 2021 virtual event. The session visited with Rockwell Automation partners that have made sustainability a priority and have committed to a positive feedback loop to continuously make processes more efficient and more sustainable. “In order to help customers meet sustainability goals, it’s important that we hold ourselves to a high standard,” Schwertner continued. “Everything needs to be managed to maintain high sustainability standards in areas such as energy consumption, operational efficiency, waste and recycling.” She welcomed three projects and organizations that are focused on sustainability for waste, energy and water.
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Chemical recycling feeds a circular economy At packaging company, Sealed Air, the makers of Cryovac food packaging and Bubble Wrap protective packaging, “We have a very high sense of purpose—to leave the world better than we found it,” said Sergio Pupkin, growth and strategy officer at Sealed Air. The company has made a pledge that by 2025 100% of its packaging will be recyclable or renewable.
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We want to recycle more in order to drive that circular economy, but the recycling stream for many of our products are still under development,” Pupkin said. So Sealed Air is driving some of that development with its customers, who share a similar recycling journey. “We have the same problems that they have,” Pupkin said. The transformation into smart factories and beyond would not be possible without automation technology and the partnership with Rockwell Automation, Pupkin added. Ron Cotterman, vice president of innovation and sustainability at Sealed Air, took attendees on a tour of the company’s innovation center at its Charlotte campus. The tour focused on three areas: one of its automated packaging lines and two of the labs where the company makes new types of packaging material and recycles plastic back into new materials.
At the food packaging lab, a Cryovac auto loader automatically inserts blocks of cheese into the package and seals them, “with a labor- and energy-efficient process,” Cotterman said. “Before that equipment was available, you would have seen a lot more people manually packaging that cheese into those plastic bags, but because of that automated equipment, it happens in a fraction of a second,” he added. “We go through a series of process steps to melt it down and to make new plastic material that performs as if it was brand-new, virgin material.. The lab is where Sealed Air does its experiments and the essential R&D work for material innovation at a small scale, before it’s practiced at the large-scale facilities. “This capability is brand-new within our industry,” Cotterman said. The final stop on the Sealed Air tour was the chemistry lab, what Cotterman called the “future of recycling,” where the chemistry is done to make plastic recyclable. “Plastic, whether in the form of a tray or film or bag, can be recycled into raw materials, such as this oil here, that can then be used to make a new plastic. We call that advanced recycling or chemical recycling and we do it because it’s not only good for the planet, but it’s also good for business,”
“ We were always about energy reduction from a cost standpoint. When the green movement started, we were already doing that ” Reducing the compressed air carbon footprint Compressed air systems are crucial to many production processes, but they often represent a plant’s largest energy consumer. Case Controls, which provides control solutions for the compressed air industry, has long been working to help companies reduce their carbon footprint with automation. “We were always about energy reduction from a cost standpoint.
When the green movement started, we were already doing that. We were already working with our customers to help them reduce energy, save costs and have a good return on investment,” said Lou York, director of Case Controls. The company also has solutions already built to help customers reduce energy consumption, without reinventing the wheel. Case can also retrofit old systems with its suite of products. “The retrofits are designed to replace and establish the same footprint as what the compressor OEM control system takes up inside the panel,” Sullivan explained. “We design and engineer a retrofit that is literally plug-and-play.”
From reclamation to revenue Where Dr. Paul Ziemkiewicz, director of the West Virginia Water Research Institute at West Virginia University, grew up in western Pennsylvania, all the big rivers and the small streams were dead from acidic mine drainage. Today, his work at West Virginia University is cleaning up the environment and those waters from the legacy mines that continue to leach contamination. Acid mine drainage typically happens when pyrite in coal is exposed to oxygen in the air and water, reacting to form sulfuric acid, Ziemkiewicz said. In 2015, the U.S. Dept. of Energy showed an interest in identifying sources of critical minerals and rare earth elements. “I talked to people in the industry. I accessed some old data sets and turns out there were a lot of rare earths in acid mine drainage that no one had ever looked at before,” Ziemkiewicz added. Over a period of about four-and-a-half years, the university developed a process for extracting the rare earth metals. “In order to make this into a commercial product, you have to be able to put feedstock in, hit some buttons and have good stuff come back out the end of it,” Ziemkiewicz said. “We couldn’t do this without Rockwell providing that automation, the sensors and control technology that make the process work.”
“ We couldn’t do this without Rockwell ” Finally, at “Site number 834,” a unit is being built to do both reclamation work on the contaminated waters and extract the rare earth elements for profit. “It is strictly treating the water coming off the #834 site that was previously contaminating the headwaters of the Potomac River,” Ziemkiewicz commented, “The number 834 site is the first integrated demonstration of our technology.” Most importantly, the process is doing reclamation work, and the treatment process itself creates a revenue stream to support the work. The full ROKLive presentation, “Sustainability: From Vision to Impact,” remains available on demand until October 2021.
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Capitalising on data-driven insights David Harding-Brown ecoveritas’ CEO believes that where there is accurate and reliable data, there is hope of achieving a truly circular economy. SPN asked Harding-Brown to expand on this theory for the benefit of our readers. Harding-Brown told SPN News. “Where there is accurate and reliable data, there is hope for a truly circular economy. According to the 2021 Circularity Gap Report, only 8.6% of our world is considered circular1. Of the 59.1 billion tonnes of greenhouse gases (GHGs) emitted in 2019, 70% of those GHGs emitted are directly linked to material handling and use, while 80% of all emissions are associated with housing, mobility and nutrition. For consumables, which includes packaging production, approximately 5.6 billion tonnes of emissions are emitted per year. Without these data-driven insights, we would not know where it is best to apply circular strategies, who should bear the responsibility and how they should be executed. This isn’t about achieving a quick win; it’s about planning for the future of our planet, economy and people.
At ecoveritas, we have more than 100 years of combined experience in providing business intelligence to packaging manufacturers, retailers and brand owners. Our expertise in data collection means we can use lifecycle assessments, footprint analysis and cost impact assessments to extrapolate meaningful figures that will support a company’s commercialisation strategy, while substantiating a circular economic plan.
With the Plastic Tax and Extended Producer Responsibility (EPR) reform coming into force very soon, there is now a major data wave on the horizon. Packaging brands and manufacturers must understand how imminent changes in legislation will affect their bottom line, where their supply chain is most vulnerable, and how gathering the right data can impact their circularity model for the better.
“ At ecoveritas, we have more than 100 years of combined experience in providing business intelligence to packaging manufacturers, retailers & brand owners ”
For example, the 2021 State of Plastic Recycling report found that consumer goods companies, plastic packaging manufacturers, government bodies and consumers should all be primarily responsible for providing effective plastic recycling resources and solutions. The survey, which was conducted by YouGov with more than 5,000 adults across the US, Mexico, Spain and the UK, indicated that these groups should have a shared responsibility to expand knowledge and influence behaviour to achieve a circular economy. This means that packaging brands, retailers and manufacturers are not alone. If collaboration between key stakeholders is the driving force behind a circular strategy, data-driven insight is the glue tying everything together.
“ If collaboration between key stakeholders is the driving force behind a circular strategy, data-driven insight is the glue tying everything together ” 28 SUSTAINABLE PACKAGING NEWS
For brands that are looking to design out waste early in the production cycle, we can also help by using key data points to minimise the environmental impact of packaging. A circular economy is not yet out of reach. Data has the power to change our future, so let’s use it while we still can”.
SILBO SPONSORED
Pushing the boundaries to close the plastic loop Dow continues to push boundaries to close the loop for plastic packaging and enable a circular economy. Through collaborative partnerships Dow is accelerating its sustainability commitments with major goals including incorporating 100,000 tons of waste plastic into products by 2025 and enabling 100% of these sold into packaging applications to be reusable or recyclable by 2035. Two recent collaborations stand out as examples of what is now possible. It all starts by designing packaging for recyclability from the outset. A recently delivered polyethylene (PE)-based pouch-to-pouch concept saw value chain partners produce and recycle a PE pouch back into raw material, successfully de-inking it in the process.
This was then used to create a new pouch, containing 30% recycled materials from the first pouch and designed for recyclability. Another ambitious collaboration used existing production lines to deliver an easy-to-recycle high barrier flexible stand up pouch. Thanks to the use of mono-material concepts, both pouches are suitable for recycling in existing PE streams. By combining Dow’s material science with partner knowhow and Dow’s Pack Studios industry-scale capabilities we continue to push boundaries to close the loop for plastic packaging.
Let us show you what’s possible: Dow.com/contact
Can we redesign plastics for circularity? We believe it is time to radically redesign how we make plastic. Let’s be honest, the plastic waste issue is contributing to environmental degradation. Our industry must accelerate the circular economy for plastics. At Dow, we are leading the charge on making this a reality. We know it’s possible to go further, faster. It all starts by designing plastic for recyclability, harnessing renewable feedstocks, and creating mono-material and recyclable packaging solutions. Increasing circularity for plastics is not easy and no one company can achieve it alone. The time to act is now. Will you join us? Dow.com/packaging
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Optimising 4R’s Southgate Packaging, one of Europe’s leading packaging suppliers, is a committed member of the industrial movement known as the ‘Circular Carbon Economy’ that aims to create a more sustainable way of working and living. To achieve this, Southgate ensures that every one of its new products meets at least one of the 4R’s: Reuse; Recycle; Reduce and Remove – and are considered the pillars of a successful circular economy. As part of its mission to be a leader in this field, Southgate invested in a specialist team focusing on new product development as part of its ongoing, pioneering activity to lead the industry in developing sustainable packaging products. In the last 12 months Southgate has launched several new sustainable products including another Paper Tape Dispenser and Void Fill, with more innovations to come. Southgate, which has more than 60 employees, is committed to developing a line of alternative products to expand its current range and significantly reduce packaging waste and plastic content. The company is determined to play a pioneering and meaningful part in persuading the packaging industry to reduce its impact on the environment and climate change.
We firmly believe that it is a must-have sustainable alternative for those using void fill and will help us and our clients contribute to the circular economy.” Southgate’s focus for 2021 and beyond will be to develop and promote the idea of a circular economy – inspiring businesses on an international scale to embrace a global solution to sustainability and eliminating waste. New product development is a major part of achieving this goal.
Craig Turner, Managing Director of Southgate Packaging, said: “With the increase in demand for packaging supplies having a knock-on effect on the supply chain, we are already starting to see industry restrictions on items such as corrugated boxes. In addition, there is also a need for warehouse space and fulfilling daily order quotas. To meet these changes we are taking responsibility by giving our customers sustainable packaging solutions, reducing waste and plastic content, whilst feeding into the consumer shift for more eco-friendly packaging products. Our mission is to have a suite of ecofriendly options available for every product.”
Southgate recently developed the PWN4 air pillow system, which is its fastest small pillow system yet. Its compact size means that it is both mobile and flexible and can be moved around easily to suit customers’ requirements. The PWN4 is the fastest machine on the market. The four speed modes of 4/6/8/10m per minute offer unbeatable speed without compromising on quality. Additionally, there is no heat-up phase, thus saving time and increasing efficiency. Craig added: “Our latest product launch is part of our mission to continually focus on product innovation and the development of new, eco-friendly packaging alternatives.
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Craig Turner
Managing Director of Southgate Packaging
We wish to play a part in the global shift towards a low carbon circular economy. Our Pure-Pak® carton solution is a premium line packaging choice. It is the environmentally friendly alternative for the widest range of liquids, making Elopak the complete industry partner for the future.
Elopak ASA | Industriveien 30, 3430 Spikkestad, Norway | www.elopak.com
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Tetra Pak tethered to a €100m pa. investment programme Tetra Pak has announced that it is to invest €100 million annually over the next 5-10 years to develop sustainable packaging solutions, including the deployment of tethered caps and paper straws. This major contribution to sustainability and the EU’s Single Use Plastic Directive, is one of many subjects covered recently in an exclusive SPN interview with Alex Henriksen, Tetra Pak’s Managing Director for North Europe, and conducted by Philip Yorke, SPN’s editor. 32 SUSTAINABLE PACKAGING NEWS
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Since taking up your new role at Tetra Pak in September last year, what do you see as the principle developments in the current packaging landscape, especially in relation to the Circular Economy? “From a European perspective, one of the most significant developments, and one of the most likely to make a positive impact, is the EU Directive on Single Use Plastics (SUP). This measure is vital for reducing the amount of single use plastic in circulation. “Another crucial proposal has been the UK’s move to put in place a Deposit Return Scheme (DRS). We have been advocating for an ‘all-in’ system that includes as wide a range of materials as possible. This sort of system would be a big step in the right direction to improving recycling rates across the UK and assisting the UK in reaching its net-zero goals.
“We are particularly keen to see carton packages included in this system. The key to increasing recycling rates for carton packages isn’t in the recyclability alone – cartons are already fully recyclable and the UK has a dedicated carton recycling facility in Halifax. It’s in the infrastructure to collect, sort and separate cartons from other recyclate. “A DRS that covers as wide a range of materials as possible, including carton packages, would help to avoid consumer confusion about what can and cannot be recycled, making the scheme function better. This would increase the environmental benefits of the DRS and help boost recycling rates.” As a flagship company, what would you say differentiates Tetra Pak from its competitors, and how do you see your role in relation to helping deliver net-zero by 2050? “Sustainability is very high on the agenda at Tetra Pak. As well as providing safe and nutritious food for people around the world, we are also committed to protecting the planet. “Our mission is to create the world’s most sustainable food package. This needs to be made solely of responsibly sourced renewable or recycled materials and be both fully recyclable and carbon neutral. “We believe innovation will help us achieve this ambition. In 2019, we were the first carton packaging producer to launch on-pack paper straws in Europe. We are currently investing approximately €100 million per year over the next 5-10 years to develop more sustainable packaging solutions. “However, recycling and de-carbonisation alone are not enough to realise our environmental goals. We need to do more to promote the use of responsibly sourced materials and employ more plant-based packaging. “Our next big goal is to achieve net-zero across our entire value chain by 2050.
The use of innovative production equipment and putting new technologies in place is vital. Yet, to reach this goal we must work more closely with our customers and our partners, who are also committed to finding more sustainable packaging solutions. That’s why we are introducing customers to more sustainable manufacturing processes and practices. We pride ourselves on the fact that we are making significant progress towards net-zero by utilising our considerable R&D facilities to drive our sustainability and circular economy mission forward.” How has the Covid 19 pandemic affected Tetra Pak’s production capabilities and manufacturing processes…. as well as its impact on your future ambitions? “This unprecedented event has affected the whole world. The pandemic disrupted the status quo and produced new, unforeseen landscapes for packaging companies worldwide. It also, understandably, increased consumer concerns about food safety and supplies. According to the Tetra Pak Index, more than 50% of consumers believe that food safety is the number one issue companies need to tackle now and in the future. “The big dilemma that we face today is ensuring that food is kept safe, while reducing the environmental impact of packaging. Tackling this challenge means we need to work more closely together with our partners across the value chain. This a vital because Covid-19 has changed the world as well as consumer habits and priorities. This shift in behaviour has resulted in the purchase of less “on-thego” products, whilst increasing the consumption of more everyday foods, with a strong emphasis on “in-the-home” consumed products. However, there are now clear signs that things are finally getting back to some sort of normality. We remain on top of our mission and committed to leading the industry when it comes to sustainability, the circular economy and net-zero emissions in 2050.” At SPN it comes as no surprise that Tetra Pak has just been named as one of the Top 50 Sustainability and Climate leaders in the world. As a global leader in the food processing and packaging industry, its pioneering spirit and commitment to achieving net-zero by 2050, has set it apart from other companies in the industry. An ever-increasing focus for Tetra Pak is its desire to tackle climate change. As a result, it is becoming an ever-greater imperative for the company. Accelerating de-carbonisation and maintaining its ongoing collaboration with partners and customers, is also seen as critical in leading the drive for sustainability transformation in the food packaging industry. By addressing the many complex and multi-faceted challenges prompted by global warming, Tetra Pak is championing sustainability, circularity and biodiversity worldwide – for the benefit of all mankind.
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Taking the lid off traditional jars Recently SPN received a moving story from a packaging company that decided that it would ‘make a difference’ having been inspired by a lady suffering from cancer. This has resulted in a valuable packaging solution. CCT tell their story via the list of questions that we created for the company. What is the background to CCT and what have been its milestones? CCT is an innovative packaging solutions company and the creator of the EEASY Lid – the first jar lid innovation in over 75 years. The development of the EEASY Lid was inspired by a friend to CCT who was being treated for cancer. She struggled to complete everyday tasks, including opening packing like vacuum-sealed jars. CCT took on the challenge of inventing a jar lid that was easy for anyone to open. The team spent the next eight years developing the EEASY Lid, ensuring its packaging was accessible to everyone – no matter age, gender or physical capability.
Company milestones include the following : • CCT announced the launch of the EEASY Lid on November 12, 2020, making opening a vacuum-sealed jar up to 40% easier with just the push of a button. • The EEASY Lid hit store shelves at Pennsylvania-based Boyer’s Food Markets on January 6, 2020. Incorporated on its Darci’s brand pasta sauce, Boyer’s became the first grocer in the country to use the EEASY Lid. • In February of 2020, CCT partnered with North Cliff Consultants to run a consumer testing study to assess the difficulty people have in opening a traditional vacuumsealed jar. The study found nearly 50% of consumers struggle to open jars, proving how ease of use affects purchasing decisions. • On May 4, 2020, CCT announced the results of the first use of the EEASY Lid over a three-month test period in Boyer’s Food Markets. Results showed that the first use of the EEASY Lid boosted Boyer’s private-label pasta sauce sales by over 300%. • CCT announced its partnerships with The Affinity Group and Trade Consult on August 3, 2020. These partnerships assist CCT in expanding the EEASY Lid’s domestic and international reach. • Just earlier this year on March 8, CCT introduced the world’s first aluminum lug lid, as it is now producing an aluminum lug version of its EEASY Lid in its new state-of-the-art technology center.
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Can you describe your product portfolio and any unique applications within the packaging industry? (EEASY Lid?)? CCT makes the EEASY Lid, the first jar lid innovation in over 75 years. The EEASY Lid comes in both a continuous thread (CT) version and a lug version. CCT’s EEASY Lug Lid is the world’s first aluminum lug lid ever made. The EEASY Lid works by simply pressing a button on the lid. After use, the lid is reclosed by pressing the button from the inside of the lid to help keep the product fresh and prevent spills. Research found the EEASY Lid reduces the amount of torque needed to twist off a jar lid by more than 40% compared to standard CT lids and 58% for traditional lug lids. What differentiates CCT from its competitors and do you offer any added-value customer services? First and foremost, CCT and the EEASY Lid were established to bring further inclusivity within the packaging industry, something you don’t see a lot of in today’s world. The EEASY Lid makes opening jars accessible to everyone despite age, gender, disability or physical ailment (carpel tunnel, arthritis, etc). CCT has also raised industry standards when it comes to jar lid packaging. Both CT and lug versions of the EEASY Lid are made of aluminum (with the lug version of the EEASY Lid being the world’s first aluminum lug lid). Most other lids in the market – specifically all lug lids – are made of steel. The aluminum CCT uses offers an unmatched combination of strength, lightweight and corrosion-resistance material, in addition to being more desirable when it comes to recycling than steel.
What are the key drivers for change in your industry sector and how is the current demand for sustainability and recycling affecting your products and productivity? “The packaging industry is constantly being driven by consumer needs. Many brands are forced to evolve their packaging as consumer needs and wants are changing. Currently, sustainability is a huge driving factor when it comes to consumer purchase decisions. Shoppers are looking to buy products that have some sort of benefit or positive impact on our environment. While many companies are updating new packaging protocols, the jar lid industry has been using the same types of lids and materials for the past 75 years. We believe the EEASY Lid – especially the new aluminium lug lid – will give companies even more flexibility when it comes to a sustainable focus”. Are you planning the launch of any new packaging products in the foreseeable future that you can tell us about? “We are currently focusing on expanding the EEASY Lid to more manufacturers and grocers across the globe. CCT is currently in talks with major retailers and national brands to potentially start incorporating the EEASY Lid on products to soon be available to consumers”.
How sustainability aware would you say that your company is and what recent measures have you taken to improve your overall contribution to the circular economy? At CCT, we are very aware when it comes to the type of materials we use to create the EEASY Lid. We knew we wanted to use aluminium on our lids instead of steel (which is what the rest of the industry uses) due to it being more recyclable. 80% of the jar lid industry uses lug lids compared to CT lids. While there have been aluminium CT lids circulating, the jar lid industry had yet to see an aluminium lug lid. With many years of research and development in the making, CCT set out to create the first aluminium lug EEASY Lid. This opens the jar lid market up to more sustainable options for manufacturers and grocers all over the world.
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How has the Covid 19 Pandemic affected your production and manufacturing processes - and future ambitions? “One of the biggest impacts of COVID-19 that we experienced was on our production facility. Along with creating the world’s first aluminium lug lid, we needed to create a custom state-of-the-art technology centre to produce a product that is a first of its kind. We saw a slight delay in getting some machinery and equipment used to produce the EEASY Lid, but we are proud to say we are officially up and running with production. Aside from minor production delays, consumers are buying food and jarred products at a higher rate during the COVID-19 pandemic – putting even more pressure on the supply chain. With that in mind, our progress has continued full steam ahead in terms of getting the EEASY Lid on potential products and in stores”. What inspired you to make a general statement about the importance of working with partners across their supply chains? “Sustainability is more than just reducing the use of plastics in products. It involves doing anything that we can to improve the world that we live in, and no one company can solve the challenge by itself. Rather, it takes everyone pushing in the same direction to make a true impact. Additionally, consumers are continuing to push brands to further invest in sustainable efforts, and studies have shown that consumers will pay more for products from companies that take sustainable measures during production. For us, the EEASY Lid can be a piece of the puzzle that helps brands improve their sustainable efforts. So, for brands to think holistically about their supply chains, it behoves them to evaluate all the partners they currently or will work with to see where more sustainable changes can be made across the supply chain. This can include changing the materials used for production or packaging to be made of recycled material, working with transportation partners who work to limit their emissions or cut down on less-than-truckload shipments or even going as far as educating consumers about how they can help with limiting food waste or encouraging them to recycle”. How do you plan to educate the food industry sector, in order to get them to rethink their packaging options in the light of increasing demand for greater sustainability from consumers? “In the food and beverage industry, companies are well aware of consumers’ buying habits, and sustainability has been trending as one of the main reasons consumers buy one product over another. As much as brands have been changing their packaging to reduce plastics and use
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alternative materials to become more sustainable, there are other things we can all do to ensure that there are natural resources for future generations. From reducing waste during the manufacturing process to working with partners across the supply chain, the little efforts each company takes to do better makes a difference in the grand scheme of things”. What do you consider to be the best way forward in promoting greater awareness of what consumers can do to incentivise converters? “We think consumers are doing their part in incentivizing brands to switch to more sustainable practices, as this is reflected in sales and market shares for a company’s products. And while it will never be 100% of consumers who go out of their way to buy products from more sustainable brands, the near 70% of consumers who do will continue to push brands to implement more best practices in hopes of attracting those consumers to buy their products. Now, it’s just up to the companies to recognize that this is a trend that will continue, and it will be up to them if they want to participate or not. Here at CCT, we planned for this to be a part of our product roadmap and developed the world’s first aluminium lug lid, which aims to be a part of that puzzle that helps brands improve their sustainability efforts”.
Siegwerk
Siegwerk
Defeating today’s down-cycling challenges Accredited as the first technology of its kind by the Association of Plastic Recyclers (APR), Siegwerk has developed a unique washable ink-technology that defeats today’s on-going, down-cycling spiral. The new technology enables de-inking of UV/ LED printed PET shrink sleeves, thus allowing for the post-recycling of sleeves, along with PET plastic bottles. Today there is a greater awareness than ever of the need for recyclable packaging. This in turn has created the development of special materials in order to develop new packaging formulas. However, there are a number of key challenges that need to be overcome in order to make 100% circular packaging possible.
One example of the application of this technology is the use of de-inking primers for cPET sleeves in combination with certified ink systems. This allows for the removal of printed layers within defined de-inking process conditions. This new technology finally avoids the down-cycling of rPET in the textile industry.
Different plastic types cannot be separated or mechanically recycled in order to yield a useful recyclate. Furthermore, avoiding multi-material structures is not always possible in respect of shelf-life and other technical aspects of the packaging. In addition, current recyclate quality is typically poor. This is due to the unpleasant visual appearance, as well as the odours that can be emitted from different types of recyclates following extrusion. These problems can also be related to ink-degrading and unwanted traces remaining in the recyclates. This process unfortunately stimulates and enforces down-cycling.
Whilst this technology may significantly enhance circularity, collaboration and close cooperation within the corresponding value-chain is key to establish a commercially successful recycling process. Therefore, Siegwerk is seeking partnerships from those in the packaging value-chain who wish to take a leading role in pioneering circular solutions for the future. Visit www.siegwerk.com or contact boc@siegwerk.com to create circular solutions for your packaging.
The importance of inks and coatings in designing packaging fit for recycling cannot be over-emphasised. Ink used on packaging can either hinder or help in facilitating true circularity and avoiding the down-cycling of packaging. To address these problems the leading ink manufacturer, Siegwerk has developed de-inking and delamination technology that enables the creation of high-quality recyclates. The de-inking and delamination primer are printable layers sensitive to an industrial hot washing progress. Inks and coatings are removed quickly and effectively, leaving clean, separated plastic layers. The remaining high quality recyclates can be used in new packaging materials. Plastic laminates do not always need to end up in the landfill or incinerator. This break-through technology from Siegwerk is compatible with a wide variety of packaging structures, whilst packaging specifications remain unchanged. Most importantly, use of the de-inking and de-lamination technology aids in achieving 100% recyclability, which is an essential component in achieving a truly Circular Economy.
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EVERTIS
Evertis
Squaring the circle for PET trays Evertis is a modern-day success story, especially when it comes to PET tray packaging. For it not only plays a crucial role in food preservation, both in terms of safety and hygiene, but also in the minimisation of food waste. This makes it today’s material of choice in terms of circularity. When it comes to the circular economy, Evertis, is the leading global supplier of PET-based films, and the one that sets the industry standard. Pioneering the incorporation of recycled content in their films for the food packaging industry since their foundation in 1959, and with the establishment of their own recycling unit in 2003, Evertis have been giving their customers the option of offering more environmentally friendly products long before there was any directives or targets in place. Evertis currently target an average incorporation of 50% post-industrial and post-consumer recycled content in their films.
Extending tray life Evertis give post-industrial and post-consumer multilayer trays a new life, thus proving that a circular economy for trays can be a reality. The firm’s partnership with a company that has a unique technology that permits incorporating recycled PET obtained from a delamination process of multilayer waste, means that it can be reintroduced as secondary raw material in their film production processes. Evertis uses raw materials and production processes, such as water-based lamination, that allow the delamination of multilayer materials during the recycling process, so that they can be reincorporated back into their films. The Evertis film production process has an EREMA reactor which allows for up to 100% of recycled content to be included in their films for food contact applications with EFSA food contact approval.
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EVERTIS
“ Evertis is delivering packaging solutions that after usage, can be recycled and reincorporated once again into new materials ” Fully recyclable PET streams The prominent levels of recycled content is not the only ambitious goal that Evertis has successfully achieved in terms of circularity, ‘Design for recycling’ is one of the top issues the company tackles together with their customers, as they view this as an opportunity to boost their film’s ability to close the loop.
Other fully recyclable solutions that Evertis has recently launched are their IR BLACK™ films, formulated with an NIR Black masterbatch that is detectable by the current sorting technology in recycling processes. This new development is a sustainable alternative that is carbon-black-free, thus improving the recyclability of the material and the final packaging. All this is good news from SPN’s perspective, as well as for all companies that are planning to meet the 30% requirement for recyclable films and are dedicated to the circular economy. When it comes to FMCG packaging in particular, Evertis appears to have “Squared the Circle” for PET trays.
To the company, ‘Eco-Design’ means the development and production of products that follow all legislation and regulations regarding food contact, whilst protecting and assuring the proprieties of the packaged product. However, of extreme importance to Evertis is delivering packaging solutions that after usage, can be recycled and reincorporated once again into new materials. To Evertis, eco-design means a circular economy. In the last few years Evertis has focused on developing innovative solutions that are fully recyclable in the PET stream. Given the close collaboration with their sistercompany Selenis, a producer of specialty polyester solutions, they have the possibility of developing resins with improved properties that can enhance the behavior and effectiveness of their films when compared with standard solutions.
“ developing innovative solutions that are fully recyclable ” Their ECOSEAL™ film, produced with Selenis Bondz MM 510™ resin, allows brand-owners to package their products in fully recyclable APET packaging trays, by replacing the usual PE layer with this specialty polyester, the need for a multilayer in the bottom web is eliminated. Furthermore, the ECOSEAL™ film’s enhanced sealing properties are compatible with universal sealing lidding films, ideal for Form-Fill-Seal packaging.
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ALBEA
Albea
Tubular step-by-step success When it comes to questions about plastic tube recycling, the answers can vary over time. New manufacturing techniques and product innovation can create additional milestones, resulting in more regulations and increased legislation. Albea believes that a clearly defined and specific methodology is crucial to achieving improved recycling results. Gilles Swyngedauw, VP Sustainability & Innovation at Albea told SPN: “Europe is driving the way towards a more sustainable future with the Green Deal and its new Circular Economy Action Plan, which focuses on 6 key areas, among these are climate change, clean and circular economy and zero pollution. In a very short time, the EU and France voted and implemented new regulations on packaging waste. And there is more to come with the revision of the Packaging and Packaging Waste Directive which will start shortly and will become the cornerstone of Sustainability in Packaging. The targets are clearly defined: In 2025, 50% of plastic packaging should be recycled, in 2030 55%, and 100% of packaging will have to be reusable, recyclable or compostable by 2035. Still, to be claimed as recyclable, all packaging needs to be collected, sorted, regenerated, and used again as a material for a viable application, which implies a multistage process”.
“ Europe is driving the way towards a more sustainable future with the Green Deal and its new Circular Economy Action Plan ” 40 SUSTAINABLE PACKAGING NEWS
Gilles Swyngedauw
VP Sustainability & Innovation at Albea
ALBEA
At Albéa, we have defined an effective methodology based on 4 concise steps:
Recycling-ready tubes and caps
Step 1 defines the packaging to assess. A tube is made
Recognised by both the Association of Plastic Recyclers (APR) in the US and RecyClass in Europe, Greenleaf is a patented, simplified web production process that generates a 100% recyclable laminate range with high barrier properties.
of the tube, a seal and a screw cap. To assess the product, the seal has to be removed and disposed. It is therefore not considered as a component of the packaging when assessing the recyclability of the tube. On the other hand, to assess the product, the cap will be unscrewed and screwed back on after each use. For the assessment, the formula should also be considered as some formulas can disqualify the recyclability of the tube.
Step 2 is about defining an existing recycling stream as
Greenleaf 2 laminate tubes
First cap in PE launched in February 2020 The SLIM Cap (flip-top) in PE is one of the lightest caps on the market, an eco-designed model combining weight reduction with recyclability.
well as the recycling family of material the tube belongs to. Where Extended Producer Responsibility is in place, the Producer Responsibility Organizations (PROs) are managing the collection and sorting the packaging by families of materials. The material making up more than 50% of the tube weight defines the family – and the appropriate recycling stream. Once the family is defined, a local recycling stream needs to be found. Finally, it should be ensured that the packaging entering the stream is not going to interfere with this one.
First extruded plastic tube & cap is recycling-ready in Europe
Step 3 is about the sorting of the tube packaging and
• • • • •
its recognition in a “materials recovery facility” (MRF). For example, black carbon or full metallised layer on surface will hinder the sortability.
Recognised by RecyClass, the tube is a mono-material, downgauged web with white masterbatch that leverages the unique Thinwall™ technology and assembled with a HDPE shoulder. Both tube ranges can be regenerated into HDPE bottles and integrate the HDPE bottles recycling stream.
Guidelines on recyclable tubes: As mono-material as possible Tube body in HDPE Cap and tube body in same material Barrier layer as thin as possible Optimized decoration
Step 4 starts when moving from the MRF to the
Regenerator plant. The compatibility of the various components with the recycling stream of its main materials family is evaluated to guarantee that nothing hinders the recyclability: Alu foil or some additives such as fibres are not compatible and can downgrade the regeneration. Some components may not impact the overall recyclability but may reduce the amount of recycled material available like PET Caps in HDPE streams.
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Sihl
Certified sustainability at Sihl Your product in individualised packaging? Quickly available, ideally in your own design and in small quantities? With ARTYSIO, we not only offer flexible and individualised packaging solutions, but can also meet your sustainability requirements! At Sihl, we combine economic success with environmental protection and social responsibility. Economy and ecology go hand in hand so that we actively contribute to a more liveable future. Environmental, social and corporate governance is our guiding principle and it sums up what we do. That is why we create products and solutions that make the best possible use of existing resources and whose sustainability has already been confirmed by various certificates. In the area of PACKAGING, recyclability is a priority for us. Three years ago, the environmental services provider Interseroh launched its “Made for Recycling” assessment procedure and thereby set a groundbreaking standard for the recycling capability of packaging.
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Sihl
The renowned company was commissioned to put the flexible packaging film 5552 ARTYSIO PACKAGING 5552 NW P&P PP M FFS 74 W to the test on the basis of its scientific assessment methods. Interseroh developed this fundamental testing standard together with the bifa environmental institute and it was then certified by the Fraunhofer Institute for Process Engineering and Packaging IVV. The company’s assessment method measures packaging against a very high standard. Only packaging that scores at least 18 points from a total of 20 is awarded the “Made for Recycling” certificate. The seal of quality is thus a meaningful indicator of the sustainability of an item of packaging. The assessment process determines whether the packaging can be easily allocated to the right capture system, how the packaging behaves during sorting and whether the packaging is suitable for material recycling. The more points the packaging scores on a scale of 0 to 20, the easier and better it is to recycle. In addition, the “Made for Recycling” service meets the requirements of the minimum standard for assessing the recyclability of packaging of the Central Agency Packing Register (ZSVR) that has been in force since 1 September 2019. Our monomaterial for flexible packaging, 5552 ARTYSIO PACKAGING 5552 NW P&P PP M FFS 74 W, has undergone this rigorous testing process and has been awarded the certificate of recyclability!
5552 ARTYSIO PACKAGING is an aqueous inkjet printable, white PP-based film that is manufactured in compliance with GMP guidelines and therefore qualifies as flexible primary packaging for food & non-food applications. The design of the product and the very fast fixing of the waterbased ink makes ARTYSIO Packaging 5552 particularly suitable for print&pack applications, where packaging is printed and filled inline in a single production step. The machinability of the monomaterial has been designed both for use on horizontal FFS systems for the filling of bulk goods and on vertical systems for the filling of free-flowing products, which hugely extends the usage possibilities of ARTYSIO Packaging 5552. With a sealing and barrier coating, ARTYSIO Packaging 5552 has excellent sealing qualities for maximum product safety, very high sealed seam strength and superb machinability on production systems. ARTYSIO Packaging 5552’s “easy opening” function also makes it simple to open in a controlled way. The excellent water vapour and aroma barrier makes the product suitable as primary packaging for products such as cereals, chocolate products, confectionery or tea. What more could you want? Benefit from our know-how, our partnerships and our ongoing support and contact us today at artysio@sihl.com or find out more at www.artysio-packaging.com
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IMA DAIRY & FOOD
IMA DAIRY & FOOD
Zero-in on new technology With its patented ‘ZERO Technology’ tools, IMA DAIRY & FOOD offers the perfect, sustainable solution for mono-materials packaging. These unique tools from the company’s ‘ZERO Technology’ range are the result of years of research and development and offer much more than simple solutions to save on materials, they also offer improved material characteristics and optimisation. In today’s competitive marketplace, IMA DAIRY & FOOD is the perfect partner for achieving innovative and practical packaging solutions. From hygienic product protection, to communication with customers IMA DAIRY & FOOD says that packaging must fulfil a wide range of functions, including packaging design, ease of use, optimal logistics, and concise customer information. However, it must also be sustainable and guarantee the shelf-life of the product. Functionality and sustainability are equally important when it comes to packaging development. This must be taken into consideration when developing alternative packaging concepts with sustainable materials such as monomaterials, as well as materials from renewable resources.
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IMA DAIRY & FOOD
When it comes to delivering a competitive edge, IMA DAIRY & FOOD’s advanced ‘ZERO Technology’ does just that. The new innovative technology can be applied to all cutting applications contained in any FFS machine. In addition it reduces maintenance costs whilst increasing the performance of the machine and provides longer punching time. By using these advanced tools, a quick switch from PS to more recyclable materials such as PET, PP and PLA can be achieved. Furthermore, customers now have the opportunity to use these materials for thermoformed products such as yoghurt cups. Only with its new, patented punching tools, can multipacks be made-up from these materials and be broken down into individual cups. In fact, this can just as easily be done as those for multipacks made from PS. Another benefit is that knives do not even have to be changed during this process using IMA DAIRY & FOOD machinery. Other special equipment in IMA DAIRY & FOOD’s ‘ZERO Technology’ range also includes special pre-heating plates, which can be easily dismantled for simpler maintenance.
In order to offer advanced sustainable packaging solutions, we work in close partnership with our customers and suppliers from the very beginning, in order to develop practical solutions for saving packaging material and at the same time take into consideration the environmental wellbeing, as well as the customer‘s product and overall packaging concept. “Together with our customers and material suppliers we rigorously test new packaging materials made from renewable or recyclable materials to ensure that the materials can be processed on our packaging machines and that the greatest possible machine output and optimisation can be relied upon at all times”
Additional savings on materials can also be achieved by using the company’s special thermoforming moulds, which offer the advantage of using thinner base web materials (foil). The result is that IMA DAIRY & FOOD’s ‘ZERO Technology’ offers companies in the dairy or food industry the most innovative solutions possible when implementing more sustainable packaging materials. This is whether it is in existing form, fill and seal machines, or in new machines. What’s more, the improved recyclability of thermoformed products provides a significant reduction in ecological impact.
“ Our technological solutions have enabled plastic packaging to become increasingly lighter over the years whilst still offering the same packaging performance ” An IMA DAIRY & FOOD company spokesperson told SPN, “Our technological solutions have enabled plastic packaging to become increasingly lighter over the years whilst still offering the same packaging performance and rigidity.
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Compostable / Bio-degradable
BIO-FED
Compounding bio-success
Possibly the most innovative research and development has been focused on the area of bio-compostable and bio-degradable packaging. This area provides the biggest challenges when it comes to such matters as sealing and multi-layer barrier protection. However, countless companies have risen to the challenge and one of the most successful is a well-known subsidiary of Akro-Plastic of Cologne, Germany. Compounding their recent success is BIO-FED, which supplies a wide range of M∙VERA® compounds for injection moulding. Their broadly diversified portfolio contains high percentages of renewable content which range from 50 to almost 100%. These materials are PLA-, PBAT- or PHA-based and certified according to standards provided by TÜV AUSTRIA Belgium. The new M·VERA® GP1045 has been specially designed for injection moulding applications. It consists primarily of renewable resources and is home compostable. It is particularly suitable for applications requiring medium stiffness (tensile modulus 2,000 MPa) and can therefore be used for a wide range of household articles, toys, packaging, coffee capsules, etc. “This compound consists of almost 100% high-quality, renewable raw materials and is excellently suited for the production of rigid objects,” says Dr Stanislaw Haftka, Sales Director at BIO-FED. A food safety approval for the EU has also been granted.
About Bio-Fed BIO-FED produces and markets biodegradable and bio-based plastics under the M∙VERA® brand. As a branch of AKRO-PLASTIC GmbH, a specialist for innovative customer-oriented plastic compounds, BIO-FED is part of the international Feddersen Group which has its head office in Hamburg. AKRO-PLASTIC and its branch AF-COLOR develop and produce thermoplastic polymers and technical masterbatches in Niederzissen, Germany. With the establishment of the BIO-FED branch in Cologne, the company expanded its portfolio to include the production of bioplastics.
“Our customers are increasingly demanding products that meet all the above-mentioned mechanical properties as well as the raw material origin and a corresponding end-oflife scenario,” Haftka adds. In his opinion, a bioplastic with a comparably comprehensive properties profile is currently difficult to find on the market. All compounds can be processed easily on common plastics machineries. BIO-FED is happy to support its customers from the first trials on, and also offers its services as a cooperation partner for the development of new products. Moreover, the R&D department of BIO-FED is constantly working on new biocompounds to fulfil further regulatory requirements and customer needs. All M·VERA® materials can be coloured individually – for example with the AF-Eco® biopolymer-based masterbatches which are certified in accordance with EN 13432. The AF-Eco® range consists of color and carbon black masterbatches as well as additive masterbatches.
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Caps – one possible application for M·VERA® GP1045
Compostable / Bio-degradable
Enhancing compostable packaging HP commented on the growing demand for more sustainable and compostable packaging: Composting and sustainability are growing issues within the packaging industry. In recent years, these issues have skyrocketed in severity. Ordering goods online and having them arrive in perfect condition on our doorstep has become expected – and as this trend has accelerated during the pandemic, so too has the amount of packaging needed to facilitate modern commerce. HP, as a leading manufacturer of labels and packaging solutions, has presented several alternatives that amidst this escalating demand for packaging will enable print service providers to offer sustainable and compostable packaging options to their customers.
“ Selected HP Indigo inks are certified as additives for compostable packaging ”
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Selected HP Indigo inks are certified as additives for compostable packaging at home and in industrial use, allowing converters and brands to print smaller quantities while helping to reduce inventory waste and improve their overall environmental impact. The inks were certified by TUV Austria according to leading EU standards which involved a series of pass/fail tests based on various criteria, such as plant toxicity and low levels of heavy metals including zinc, copper, nickel, cadmium, and mercury.
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Compostable / Bio-degradable
Crunch-time for crisps
An innovative packaging company in Poland has recorded a first when it comes to the packaging and content of organic crisps. We take a closer look at the 100% natural, compostable and biodegradable product that appears to beat all others!
Silbo is a dynamic Polish packaging company that was recently given the assignment to devlop new bio-degradable packaging for a eco-friendly range of organic crisps. Flax is a new bio-snack, and its main ingredient is linseed! Its composition is simple, natural and, most importantly, healthy. This ‘healthier diet’ product had to be packed in an environmentally friendly way that was both compostable and biodegradable.. Martyna Smolenska, the commercial director of the crisp manufacturer: ”The Good Stuff” told SPN, ”When we started this project, we were concerned about the ecological values of the packaging, we were looking for a biodegradable material that would meet our high organic and aesthetic expectations. We wanted something original that would be different from what could already be found on the market”. The answer to this challenge was met by Silbo a leading food packaging company that developed special biodegradable packaging entirely from compostable materials. These decompose in appropriate industrial conditions and change into valuable organic matter in a neutral, harmless way for the planet. After use, such packaging can be discarded into a Bio container. The laminate made by Silbo (a multilayer compostable material) is not only about environmentally friendly raw materials, but also about high-quality printing with water-based inks. These do not release harmful substances into the soil and do not emit poisonous compounds into the atmosphere (as is currently the case with solvent-based printing). Silbo has been using this type of water-based printing for six years now and was the first in Europe to produce fully compostable flexible packaging. We have been told that there is still a general belief that compostable materials in packaging do not provide adequate barrier properties. According to Silbo this is a myth. They say that such bio-barrier materials are already available and combinations of renewable raw materials have been developed that meet all specific barrier requirements. In addition, they have excellent resistance to moisture, which as a result, offers secure barriers to gases and aromas.
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Interestingly, they are also resistant to oils. Thanks to this, the chips can remain pleasantly crunchy and tasty, whist the packaging remains hygienic and functional. Silbo tells SPN that similar bio-packaging solutions are not only ideal for all kinds of snacks, but also for coffee, convenience dishes, instant products and even dietary supplements. Smolenska of ‘Good Stuff’ foods commented, ”We like the approach that Silbo has developed towards its customers. We got to know the owner,and the company’s portfolio is impressive. We also appreciate the knowledge that was passed on to us during our on-going discussions. We are not aware of any other food packaging manufacturer that offers such solutions with such pro-ecological properties” Altogether this sounds like a recipe for environmental success. We endorse the innovative approach to the production of compostable and biodegradable packaging and anticipate that Silbo will be kept very busy by eco-aware food packaging companies throughout Europe!
Compostable / Bio-degradable
Bio-Packaging under the microscope Exploring advances in environmentally friendly polymers for food packaging is something that is gaining momentum throughout the industry. Plastics have received much criticism in recent years, however, finding a like-for-like alternative is incredibly challenging. So how viable are these new greener plastics? Ben Smye, head of growth at materials search engine Matmatch, takes a closer look. The food industry is one of the sectors that has benefited most from the developments in plastics in the past century. Just as refrigeration revolutionised preservation of food for consumers, plastic packaging reshaped product possibilities and food distribution. Plastics provided an effective, massproducible means of extending the shelf life of products by protecting them from oxidation, microbial growth and some damage during transportation. To this day, thermoplastics are widely used for the majority of food and beverage packaging. This is due to their flexibility, impact resistance, lower molecular weight and, crucially, their ability to be recycled. However, being recyclable is not enough on its own.
Since it has become apparent that plastic is often not being disposed of properly or the infrastructure is not in place to support recycling of all plastics, the need has arisen for other environmentally friendly alternatives. Several materials such as paper, glass and aluminium have grown in popularity for food packaging in recent years. But as any design engineer knows, simply substituting one material for another is not straightforward — the properties of the original material and its replacement need to be taken into consideration. This has led many food packaging companies to consider biodegradable and compostable polymers, which can exhibit comparable properties to conventional plastics.
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Compostable / Bio-degradable
Defining Degradation The degradation process that a polymer goes through helps to define whether it is biodegradable or compostable. In the case of the former, the polymer decomposes into carbon dioxide, water, inorganic compounds and biomasses in certain controlled environments, such as under high temperatures or when exposed to certain chemicals. Compostable polymers, on the other hand, are defined much more closely. European standard EN13432 requires that any plastic that’s marked as ‘compostable’ needs to break down under industrial conditions — in temperatures of up to 60 degrees Celsius — in under twelve weeks.
“ there are many biodegradable polymers that are proving themselves to be valuable in food packaging” Within these definitions, there are many biodegradable polymers that are proving themselves to be valuable in food packaging. Natural polymers such as cellulose can be used as films and fresh produce packaging; non-natural polymers like polyglycolide (PGA) can function as the protective layer in multi-layer packaging; and synthetic polymers, notably Polyhydroxyalkanoates (PHA), can be used in bottles and containers. Where biodegradable and bio-based polymers have historically faced limitations, however, is in scalability and compatibility with existing processing methods. But the increased drive in green polymer innovation in recent years is helping to overcome these hurdles. Polylactic acid (PLA), for example, is receiving a lot of interest in food and beverage packaging. This interest has arisen due to its thermal and mechanical properties, as well as its compatibility with processing methods such as injection moulding, film extrusion and thermoforming. These properties have led to it being researched and used in areas like food trays, disposable straws and lids.
Progress via Partnership Matmatch works in close partnership with many materials suppliers globally, several of which have ongoing developments in the field of more environmentally friendly packaging substances. One such company is Total Corbion PLA, a leading producer of PLA, a biobased and biodegradable polymer that can be used in packaging applications. Made from renewable sources, PLA offers a reduced carbon footprint when compared with traditional plastics. A number of PLA materials have been food contactapproved, and as development continues on their Luminy portfolio, Total Corbion PLA is providing innovative and biobased solutions to packaging problems.
“ With so much research and development in the pipeline, the future of environmentally friendly food packaging looks to be full of ground-breaking ideas ” Another company is Stora Enso, who focuses on bio-based materials. ‘Bio-based’ means the materials are produced from renewable feedstock rather than oil-based sources. Stora Enso is a leading global provider of renewable solutions for packaging. The company’s goal is to move away from fossil-based materials and, as such, their products offer a lower carbon footprint than traditional plastics and often have superior recycling properties. With so much research and development in the pipeline, the future of environmentally friendly food packaging looks to be full of ground-breaking ideas. And with companies like Matmatch connecting design engineers with materials suppliers that can fulfil their requirements, it seems that there’s a revolution in food packaging just on the horizon.
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Compostable / Bio-degradable
Orbis
Bio-packaging goes orbital In recent years Orbis has invested heavily in order to make the Circular Economy a reality. Today it looks as if Orbis has made considerable progress towards achieving their goal. SPN takes a closer look at the latest developments at Orbis, by sending them some pretty searching questions. The results are published here. 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? “As a manufacturer of plastic transport packaging for many decades, ORBIS’ key principles are Innovation, Durability & Sustainability. Today, sustainability is implemented in the entire product life cycle, from inbound processes and production to recycling. ORBIS goes even further to find new ways of contributing to the circular economy”.
ORBIS Lithium Ion Battery Transport box
In relation to sustainability, what would you say have been your most important milestones? “Making transport packaging solutions as sustainable as possible has always been a priority at ORBIS. That is why we use recycled materials wherever possible in production, design our products to have a significantly longer lifetime and recycle 100% of the raw materials”. In your opinion what have been the most significant developments in terms of recycling and bio-degradable packaging? “Using recycled materials for packaging production can be a challenge. ORBIS designed products to be extremely robust and durable – while using recycled materials. In the US, ORBIS recently launched its Ocean in Mind packaging initiative, which focuses on recovering and repurposing single-use plastic waste found on coastlines and using it in supply chain packaging”. What do you consider to be the most promising market opportunities for your company at this time? “With rising sustainability targets, ORBIS is looking to address new vertical markets with reusable & recyclable transport packaging to replace one-way packaging”.
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 replacement of metal glitterboxes & corrugated packaging is driving more efficiency and sustainability in industrial supply chains. Also, ORBIS Europe pioneers in developing customer-specific packaging solutions for dangerous goods (e.g. li-ion batteries). As sustainability is a key pillar of our strategy since many years, ORBIS is well prepared for the challenges regarding sustainability and addresses these globally with a wide range of sustainable products and manufacturing processes!
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A Better Way
Compostable / Bio-degradable
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? “In the industrial sector, the development of complete packaging solutions (including dunnages) and UNcertification, if necessary, combined with a wide product range of different sizes is key. In RSC, ORBIS is going to launch different kinds of innovations to replace one-way packaging within the next years and make FMCG supply chains more sustainable”. Can you describe your product portfolio and its sustainability credentials? “ORBIS’ product range consist of a wide range of FLC bulk containers, pallets and totes. Each of these product lines has their own credentials when it comes to sustainability. •
Usage of used water & green energy in our plants
•
CO2 reduction in production process
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Significantly longer lifetime of products
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Buyback & 100% recycling
•
See sustainability infographic for additional input on pallets & totes*
Are you planning the launch of any new products in the foreseeable future that you can tell us about? “ORBIS will be launching a sustainable and efficient plastic alternative corrugated / one-way packaging in Nov 2021 (@Sustainability in Packaging Europe & Deutscher LogistikKongress). The boxes have identical features as cardboard boxes. So, they are ideal for applications with closed supply chain loops (e.g. inbound packaging, finished goods) and compatible with existing automated and manual processes. The reusability (70+) and recyclability bring significant added value to customers’ supply chains:
•
Long-term cost-savings
•
Significant source reduction
•
Improvements in operations
Our sustainability journey continues. With a new product concept, we have set another milestone in making FMCG supply chains more sustainable”. How has the Covid 19 pandemic affected your production and manufacturing capabilities? “Not at the beginning. There is always a need for transport packaging to keep supply chains running. Of course, like every company operating in global markets, ORBIS is affected by the current price increases in logistics and raw materials”.
For a more sustainable business, start with your supply chain.
Why use reusable over single-use packaging? less system downtime
faster load/unload times
lower labor costs
Small footprint. Big savings. 38,000 Equal to ttles 2-liter bo
REUSABLE TOTES1
R E U S A B L E PA L L E T S 2
31%
71%
79.5%
72%
38.3%
3.2%
Reduce energy usage
Enough to ru a refr igerat n or in 12 0 U .S. hom for 1 ye es ar
Reduce energy usage
Reduce solid waste
Reduce solid waste
Reduce greenhouse gas emissions
Reduce greenhouse gas emissions
Reusables help companies build a more S U S TA I N A B L E B R A N D
reusable pallets last 18 times longer than wood pallets.4
90%
REUSABLE
of consumers want companies to do more than turn a profit
Up to
75%
200 cycles WOOD
11 cycles
of consumers expect businesses to support efforts to stop climate change3
Supply chain optimization with reusable packaging products Long-term cost savings
+
Rapid ROI
=
packaging management services
Better operational efficiency
Lower environmental impact
Our circular economy
Continuous flow of product for a sustainable supply chain
REDUCE
REUSE
R E C YC L E
Reusables are designed to lessen waste, greenhouse gas emissions and energy use.5
Sustainable for many trips over a number of years.
Manufactured, used, reused and reprocessed with zero impact to the solid waste stream.
Our commitment to sustainability
97%
99%
products are recyclable at end of service life
products eliminate the need for single-use packaging
water used in manufacturing operations is reused
100%
reusable packaging products are designed for sustainability
Get credit for sustainability
52 SUSTAINABLE PACKAGING NEWS
*
The Recycle with ORBIS program recovers, recycles and reprocesses end-of-life customer packaging back into useful product. Often for a credit for future implementations. LEARN MORE
DOWNGAUGING
Downgauging without compromise Packaging companies throughout the UK are seeking ways to avoid the heavy tax shortly to be levied on all those who do not include 30% recyclable material in their products. Wrap-film is one important area where this can be easily and quickly overcome. SPN asked Rick Sellars, Head of Sales at Lindum Packaging, what he considers to be the best way forward for those who are still seeking the quickest and most cost effective options. Sellars told SPN, “In less than a years’ time the Government will begin taxing UK businesses at the rate of £200 per tonne of plastic that does not contain 30% recycled material. In order to avoid this new burden of increased costs, you may be considering switching your current pallet wrap film for one with 30% recycled content. Firstly, think about ways you can reduce the amount of plastic you’re responsible for by looking at high performance films. If you have been using the same stretch film for the last few years, it’s definitely worth evaluating possible alternatives.
Optimised pallet-wrapping “Many businesses are saving money, reducing plastic content and improving pallet stability by using high performance stretch films which have been correctly optimised on their pallet wrappers. High performance multilayer nano materials can stretch up to 50% further without compromising strength or puncture resistance. In any event, the switch is usually a simple matter of making a minor adjustment to existing machinery. As a transit packaging material, unseen by the consumer, the environmental impact of pallet-wrap isn’t often mentioned, but with stretch film usage in the UK estimated at 140,000 tonnes annually, the environmental impact of downgauging is considerable. However, selecting the correct stretch film depends on its application and it is also important to assess all stages of the pallet’s journey before choosing a thinner film. In addition, it is worth considering the type of product it will wrap, the distribution process and the wrapping machinery, all of which can influence the outcome.
A key tool “This is where optimisation and pallet stability testing is critical. Rather than simply choosing a thinner film, optimisation is vital to ensure that the right film is being used within your specific packaging lines and operations. Testing offers even more advantages as many pallets are damaged in transit and returned, thereby causing reworking and additional plastic in order to resolve the problem. Testing is not only a key tool for optimisation, but is also an important tool to reduce product damage. Furthermore, it can help to define the best film possible for your operation, whilst using the minimum amount of plastic. So when it comes to downgauging, rather than thinking about how light you can go, you should aim to downgauge as far as possible without compromise, whilst still ensuring that the wrap provides optimal product protection. This approach will not only help you reach sustainability targets, but save you time and money too.” concluded Sellars. This rational view of how to quickly and effectively to resolve the impending plastic content tax, makes a lot of sense to us. Especially forClose-up those who wrestling with thecleaning many ofare water jet machine challenges that confront our industry today. This is one solution that can readily tick all the right boxes.
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2021 RISE Bioeconomy
footprint of carton packaging against alternative solutions
Tackling Carbon Emissions
A comparative analysis of the cradle-to-grave carbon footprint of carton-based solutions against the cradle-to-grave carbon footprint Comparing the carbon of alternative packaging solutions A ground-breaking report by the Pro Carton Association footprint of carton
packaging against Biogenic removals refer to CO2 uptake from the atmosphere through photosynthesis during biomass growth. alternative solutions
PRO-CARTON, the European Association for Carton & Cartonboard Manufacturers has just published a groundbreaking, life-cycle-analysis report, that highlights the outstanding environmental advantages of cartonboard packaging when compared to its fossil-based alternatives.
Pro Carton General Manager Tony Hitchin commented: “Whilst the unique aspects of the life-cycle of fibre-based packaging are taken into account when calculating the total carbon footprint, we also wanted to see what the results would be when only the fossil green-house-gas (GHG) emissions were considered and the cartonboard solutions gave a favourable result.”
The study, carried out by RISE (Research Institutes of Sweden) Bioeconomy unit for Pro Carton, and peer reviewed by Intertek, provides a unique insight into the relative carbon footprints for packaging in different consumer A comparative analysis of the cradle-to-grave sectors, with detailed explanations of the factors driving carbon footprint of carton-based solutions The full report can be found here: the comparative results.
against the cradle-to-grave carbon footprint www.procarton.com/publications-news/publications/ of alternative packaging solutions
Cartonboard proves its life cycle credentials
Published in June 2021, Cartonboard Life Cycle; Comparing the carbon footprint of carton packaging against alternative solutions, goes into the granular detail of the cradle-tograve environmental performance of cartonboard in frozen food, ready meal, fast food and small electricals packaging, compared to other commonly-used packaging materials, such as multilaminate film bags, PP trays, PET trays and PVC blister packs. RISE’s cradle-to-grave comparison ensures that the entire lifecycle of packaging is taken into account – from how it is produced (or grown in the case of the wood used in cartonboard manufacture) to processing and disposal. The study reports both fossil green-house-gas (GHG) emissions and biogenic GHG emissions and removals.
www.procarton.com Fossil GHG emissions arise from non-renewable sources
such as fossil fuels, while Biogenic emissions arise from the combustion of biofuels and the degradation of bio-based products.
www.procarton.com 54 SUSTAINABLE PACKAGING NEWS
2021 RISE Bioeconomy
Cartonboard Vs Fossil Carbon Emissions
Tackling Carbon Emissions
Carbon footprint cut down to size News just in to SPN confirms that 3T has wrapped up a significant new contract with the UK’s PFF Packaging Group. This to install its new, advanced transport management system designed to streamline its customer’s deliveries and reduce its own Carbon footprint. The PFF Group is a major supplier of packaging products to supermarkets and food manufacturers throughout the UK, as well as being a leading producer of disposable aprons for the NHS. 3T Logistics and Technology Group has recently been selected by one of the UK’s leading food packaging manufacturers to streamline their customer deliveries and help reduce the company’s carbon footprint. Food packaging manufacturer PFF Group has recently invested in a new transport management system to supply packaging products to supermarkets and food manufacturers across the UK. With increasing changes to their logistics needs due to the continuing pandemic, PFF Group selected 3T as the ideal partner to help them fulfil their growing supply chain requirements. PFF Group currently also manufactures disposable PPE aprons which are despatched from the company’s Washington site to Department of Health and Social Care depots and distributed for use by NHS frontline health and social care workers. This will be an important element of the new transport management system which utilises 3T Logistics and Technology Group’s cloud-based software. 3T has a proven track record and enviable reputation in the logistics sector for its supply chain and transport management solutions. PFF Group will benefit from this expertise through the platform’s capability to consolidate loads and optimise vehicle usage, thereby reducing journeys and lowering carbon emissions.
“We see the introduction of our TMS solution as a critical step in PFF’s digital transformation. PFF has a vision of reducing carbon footprint and with our transport management system, we will automate and optimise PFF’s transport operations, giving the firm full control of its transport management and bringing greater levels of transparency and visibility. “The collaboration between 3T and PFF showcases two fast-growing British businesses with a global outlook that are using technology to drive efficiency and innovation. We look forward to working with PFF and providing the logistics solutions it needs to scale their business and further accelerate growth.” Today 3T is working with a number of high-profile companies across industry verticals, which value a logistics partner that can help them achieve their service, cost and environmental targets whilst digitising their supply chain.
Lee Wilkinson, the PFF Group’s supply chain manager, said: “We work with a pool of hauliers and the software enables us to select the best carriers for locations where we can do multiple drop deliveries. By making sure we have filled the vehicles, we are reducing costs and the environmental impact as the amount of carbon per pallet delivered is reduced. The new system also tracks delivery lorries to ensure they arrive on time and manages proof of delivery. This means we are improving service to customers who are increasingly seeking suppliers with reduced carbon usage.” Rob Hutton, sales and marketing director at 3T Logistics and Technology Group, believes the new partnership with PFF Group will see a reduction not only in costs for PFF Group but also in its environmental impact.
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PROMATERIS
Promateris Packaging Thanks to a continuous programme of investment and innovative R&D, the leading sustainable packaging company Promateris is extending its bio-packaging operations throughout the CEE region. Following its continuous strategic investments in stateof-the-art technology, R&D and IT infrastructure systems, Promateris has significantly extended its operations in order to distribute its products to multiple CEE countries. These include Greece, Poland, Moldova, Bulgaria, Hungary among many others. This move is part of the Promateris’ strategic expansion plans in the region for its bio-based and compostable packaging products. This fast-paced expansion programme is the result of a series of major investments that exceeded more than EUR 10 million over the last 3 years. Much of these funds went to further developing its facility near Bucharest, Romania, which is dedicated to processing bioplastics derived from renewable resources. Following these investments, the company plans to consolidate its leading position in the CEE region, whilst continuing to enhance its current, on-going investment policy.
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PROMATERIS
The Promateris team
Promateris R&D team, we are able to manufacture products with a reduced environmental footprint. Our strategy includes the manufacturing of products that respect the principles of circular economy”, declares Tudor Georgescu, CEO of Promateris’.
Digital transformation is a priority for the Promateris’ management team. Celebrating more than 60 years since its foundation, the company has undergone major transformation in order to implement up-to-date business processes and manufacturing operations. In 2021, together with their German partner, Theurer, Promateris will implement an ERP/MIS specialized in manufacturing, thus enabling real-time information & insights, as well as advanced automation and production cost optimization. Furthermore, Promateris is extending its European sales network, as well as its product portfolio. Tudor Georgescu, CEO of Promateris: “We consider this to be perfect timing for the expansion of our product portfolio, thereby addressing more of our clients’ needs. We will also develop new products bearing in mind two important things: the circular economy principles, and the modern, sustainable retail shelf. We are determined to offer a new generation of packaging, whilst setting an example of best sustainability practices for other companies.” In the future, the Promateris Group aims to develop three new divisions to strengthen its presence in the new markets in which it has recently started operating.
1. Biomaterials - strengthening regional leadership and investing in the production of value-added, flexible bio-compostable packaging for the food industry. 2. Recycling - reducing the volume of virgin plastics used in the production of packaging and replacing them with recycled materials, respecting the principles of the circular economy. 3. Paper - development and production of sustainable solutions, based on paper and biomass, taking into account the biodegradability, regenerability and recyclability of new materials. Promateris is a leading European manufacturer of sustainable products and solutions for the circular economy. With a history of more than 60 years in packaging manufacturing, Promateris has gained regional leadership and top manufacturing expertise in chemical engineering. The Promateris Group invests in developing sustainable packaging products and solutions for the circular economy, R&D and end-of-life solutions. The company also operates a plant dedicated to manufacturing specialty compounding for technical applications. Active in Bucharest, Valencia and Warsaw through commercial offices and through distributors in more than 20 countries and 3 continents worldwide.
For more information visit: www.promateris.com
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RECYCLED MATERIALS
Putting the ‘R’ into PET
Earlier this month Mondelēz International announced that it will use recyclable packaging for its Dairylea and Philadelphia brands in the UK and Ireland from August 2021. The move away from non-recyclable material is part of the company’s Pack Light and Pack Right strategy, which supports its vision of achieving 100% recyclable packaging by 2025. Dairylea Lunchables will now use recycled plastic (rPET) in its packaging – “the result of a design optimisation project reducing the virgin plastic needed by 75% or approximately 276 tons per annum,” said a company spokesperson. In the meantime, Mondelēz’s Philadelphia brand will become the “first major cheese brand” to use chemical recycling, set to be in place by the end of 2022.These actions are all part of the company’s wider goal which is to reduce the use of virgin plastic by 10,000 tons in five years.
58 SUSTAINABLE PACKAGING NEWS
“ I am enormously proud to share this latest move on our journey towards our 2025 goals to better protect people and planet ” Louise Stigant, UK managing director at Mondelēz International, said: “Snacking Made Right means making our products with packaging people can recycle, it means making decisions for the long term that enable a circular economy. I am enormously proud to share this latest move on our journey towards our 2025 goals to better protect people and planet.” No doubt that there will be plenty of other beverage and food companies following suite sooner rather than later!
RECYCLABLE. COMPLETE.
VERIFIABLE. KURZ
LEONHARD KURZ Stiftung & Co. KG Schwabacher Str. 482 90763 Fuerth/Germany Phone +49 911 71 41-0 Web: www.kurz-world.com E-Mail: sales@kurz.de
With KURZ transfer technology, only extremely thin and demonstrably pollutant-free decorative layers are transferred, not foil. Therefore, the recyclability of products finished with it is clearly not impaired. Learn more: www.kurz-graphics.com/nofoil
making every product unique
Recycled Materials The Eco2web machine
Safety in numbers
Two companies at the top of their game have joined forces to launch the world’s most advanced barrier coating machines. They are offering sustainable water barriers that can be heat-sealed. This is a first for the packaging industry and this new US/EU jointventure adds up to numbers that will make the deal unmissable. In fact, the fast and generous ROI alone makes this a most attractive proposition.
Lennart Group B.V & EcoSafe Barrier Inc have launched their unique EcoSafe Barrier Coating Machines this month. Ecosafe Barrier Inc, is a US producer of paper coating machinery with many patents already under its belt. Now the company has joined forces with the Lennart Group B.V of the Netherlands, to create an EcoSafe barrier coating machine that offers recyclable, sustainable coatings for packaging markets worldwide. The aim of the partnership is to eliminate plastic materials throughout the industry. This ground-breaking project was launched last month following the success of the company’s water barrier coatings which were tested specifically with recycling and sustainability in mind. From today, all machine models will be built and shipped from the USA by Ecosafe Barrier Inc. The coating systems are specially made for water barrier/ heat seal/ultrasonic seal coatings for optimal performance. For example, the Eco2sheet is a double coating line for sheets measuring 50cm X 70 cm and 77 X 108 cm. The Eco2web machine is a double coating line for sheet sizes 52cm and 77cm widths. These sizes will also be upgraded in the near future.
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“ The aim of the partnership is to eliminate plastic materials throughout the industry ”
The Eco2sheet is a double coating line for sheets measuring 50cm X 70 cm and 77 X 108 cm
Recycled Materials
“ we believe that companies should work closely together to reach zero-plastic levels as soon as possible” The water-based coatings are made in the EU by our existing partners with each coating being specially made for our machines. There will also be a number of new developments to come soon for both coatings and machinery. I.Cem Yaray, Co-Founder of Lennart Group B.V, said; ‘’We have been working on the project for the last 18 months and have achieved many goals. EcoSafe Barrier Inc has in-depth knowledge of advanced coating machines. Our coating producer partner has also worked closely with us to create the best possible sustainable coatings for our machines. We all know that plastic is very harmful to nature and to our environment. This is something that we are committed to changing. Furthermore, we believe that companies should work closely together to reach zero-plastic levels as soon as possible. To this end, we will be supplying our environmentally-friendly machinery and coatings in tandem for our customers” Yaray added, “Our target is to develop production flexibility for packaging companies whist helping to achieve zeroplastic content in all packaging. Companies do not need to buy different types of cartons in stock. Depending on order types, they will be coating their cartons on Eco2 machines with our eco-friendly, sustainable coatings, whether this is for high volume runs or simply short-run sampling. The order amount is not important to our system, as the coating costs are so low. R.O.I of the machine is fast and generous. Right now, companies are struggling because of their raw material costs and other variables. Lennart Group B.V. is always looking for cost-reduction possibilities for its clients. In addition, if we are helping the world to reduce global warming, we will also be the happiest people in the world‘’. Here are a few of the sectors that Eco-Safe told SPN will be the first to benefit: • • • • • • • • •
Fast Food packaging Bakery Packaging Flexible Packaging Aluminum/Film Lids Paper Cups/bowls Pouches Medical Packaging Hygiene Packaging Lamination film replacement in packaging & printing
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BW FLEXIBLE SYSTEMS
The Growing Pains of Sustainability in Packaged Foods Michael Dann, BW Flexible Systems’ Global Product Line Leader for Horizontal Form Fill Seal, asks: “How can we as an industry satisfy consumer demand for ‘sustainable packaging’ when the term is still being defined?” The answer is, of course, complicated. BW Flexible System’s approach to sustainability recognizes that the pathway to truly sustainable manufacturing and packaging needs to be flexible and will require addressing not only the material being used to package products, but the packaging machines and even the manufacturing facility, itself. To accomplish this, the flexible packaging company is setting some ambitious targets and investing in research and development with the intention of leading the way to a cleaner, “greener” packaging future.
Research and Development One of the major targets in a sustainable packaging strategy is to facilitate the use of recyclable and compostable film structures. In the current market, that means packaging machines need to be able to form, fill, and seal paper, polypropylene (PP), polyethylene (PE) and other widely recyclable films. Further, using thinner films helps to reduce both waste and bulk, but also has the effect of ratcheting up the complexity of creating quality seals. Recently, BW Flexible Systems partnered with a major film producer in Vienna to develop performance recyclable films for use in horizontal flow wrappers. This partnership not only resulted in film structure development, but advanced BW Flexible Systems’ technology for forming and sealing recyclable and downgauged film structures without compromising seal quality.
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Paper presents other challenges. Requiring gentler handling than plastic, paper material must still run at the same line speeds as plastic materials. To address this, BWFS studied, tested and answered a handful of underlying technical challenges while developing solutions for its existing Vertical Form Fill Seal machinery. Compared to plastics, running paper makes it more difficult to create a quality seal, particularly while the film is running continuously. To solve this, BWFS again partnered with innovative sealant manufacturers and made modifications to the forming tube assembly (FTA), specifically accounting for the time and temperature required to properly seal bags from a customer’s chosen material. The flexible packaging manufacturer also developed a cold punch system to punch peg holes, that is now used across other BWFS packaging systems that handle paper.
BW FLEXIBLE SYSTEMS
“We understand the increasing need of our customers to meet sustainability commitments. At the same time, we recognize the current challenges with labor shortages and the demand our customers have for automation. These challenges, together with increased competition among brand owners, are creating a profound transformation in the packaging industry,” says Michele Allamprese, Vice President of Europe for BWFS said. “The opening of the Technical Center will allow us to fully support our customers through that transformation.” Paper bag samples for Golia Italia lozenge brand
Thinking beyond paper and plastic Of course, there’s more to developing sustainable, environmentally conscious packaging solutions than film structures alone and BW Flexible Systems has spent considerable time and effort to bring innovative solutions to market that help customers reduce film and product waste, eliminate unexpected downtime, and reduce operator error to help produce more good output per shift. BWFS has begun rolling out a powerful new, intuitive HMI that helps machine operators more efficiently set-up and run their packaging equipment. Partnered with features like the company’s several film alignment features across both vertical and horizontal platforms, these innovations help reduce wasted material. This focus on reducing waste has two effects: it creates a more sustainable packaging environment for customers and improves their yearly EBITDA. In effect, by delivering the lowest cost per pack for the customer through ecoconscious improvements, BW Flexible Systems is also helping the environment.
Partnering to meet specific requirements
BW Flexible Systems has also been busy opening new regional sales and service facilities in areas such as South Africa and Russia, providing local sales and support to better meet the challenges in those markets while also reducing corporate travel.
Sustainable manufacturing practices Finally, manufacturing these solutions should also be as sustainable as the flexible packaging machinery itself. To this end, BW Flexible Systems is charting a path that will see the packaging solutions provider begin seriously tracking and reducing its carbon footprint. Planned future projects include utilizing solar power with a goal of eventually reaching 100% renewable energy usage in the near future, updating plant heating systems from gas to heat pump, and replacing doors and windows with triple glazing in order to boost energy efficiency. The company also plans to update its corporate car fleet with a mix of plug-in hybrid and allelectric vehicles and will add charging stations at its plants. The road to more sustainable packaging will involve collaboration, innovation, and flexibility across a broad range issues and solutions. BW Flexible Systems’ focus on research and development, collaboration with customers and partners, and development of sustainable manufacturing processes shows the company is poised to build a more sustainable packaging future.
Of course, sustainable packaging will never be a “one size fits all” endeavor. The differing nature of products to be packaged, varying regional and local requirements, and the demands of different markets means that a certain amount of flexibility will always be required of a packaging solutions provider like BW Flexible Systems. This is why partnering with producers, who intimately understand these issues and their products, is an essential component to delivering truly sustainable packaging solutions. The newly opened Center for Technological Excellence in Nottingham, UK, BW Flexible Systems’ new state-of-the-art facility, is intended to provide customers the opportunity to collaborate on packaging solutions by gaining hands-on experience and testing machinery using their product and film types before installation. This will include an intentional focus on developing sustainable solutions.
A sample paper bag displaying seal integrity and punched hanging display hole
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Consumer impact MACHINERY
Impact report re-enforces commitment A leading Multi-Cultural rice brand takes a stand on sustainability with the launch of the TILDA® Impact Report 2021 In its 50th year of trading, Tilda® calls for honesty, transparency and a pre-competitive spirit to tackle the climate crisis as it launches its first ever Impact Report. As it seeks to be one of the most responsible rice producers in the world, the Tilda® Impact Report 2021 reinforces that promise by mapping out the brand’s operations, impacts and solutions for change. Tilda’s® commitments are based around three focus areas: sourcing, manufacturing and packaging, with support for communities at the heart of its approach. The report outlines progress in each of these areas and sets out new commitments to drive improvement and transparency: Responsible sourcing : Tilda® works with over 7,000 farmers in India who are involved in its Farm Extension Programme to ensure fair livelihoods and protect the environment through good agricultural practices. 50 farmers are taking part in Tilda’s feasibility study to explore how methods to reduce greenhouse gas emissions and conserve water in rice farming can be scaled up across the sector. This is key to raising standards and guaranteeing that rice is produced in a way that safeguards people and the planet. In recognition of its commitment to responsible sourcing, Tilda scored 100% for ethical performance and transparency in its supply chain.
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State-of-the-art manufacturing : With the electricity used to make its products coming from 100% renewable sources since 2020 and an 18% reduction in its carbon footprint since 2017, Tilda® is committed to reaching Net Zero emissions in its manufacturing by 2040 through innovation and investment. Circular packaging : Tilda continues to evolve its packaging to reduce its impact by light-weighting, introducing recycleready packaging and facilitating recycling of its current packaging in the market. Committing to 100% recyclable packaging by 2025, Tilda® is supporting the UK’s Flexible Plastic Fund to enable all its current packaging to be recycled at collection points being rolled out by leading UK supermarkets in 2021. The brand will have a fully recyclable plastic pouch in market this year, ready for when kerbside recycling begins. Making a positive impact on Communities : With it’s commitment to tackling hunger and food poverty, Tilda has donated over £1m since 2013 to deliver life-saving nutrition in Bangladesh in partnership with the World Food Programme. It increased its assistance to UK communities during the pandemic through its long-term collaboration with the Felix Project.
Consumer impact SPONSORED
Reduce waste with banding. Reduce Reduce waste waste with with banding. banding. Learn how replace Learn Learn how how toto to replace replace conventional packaging. conventional conventional packaging. packaging.
It is well known that banding can reduce packaging material. New material developments ensure that paper banding suitable for ultrasonic welding also has less than 5% foreign material.
ats-tanner.com ats-tanner.com ats-tanner.com
Good to know: ATS not only has paper banding films on offer, but also those made of plastic. All banding films are made of high-quality mono-material (PP, HDPE) and can be recycled just as well.
For paper bands to be welded with energy-saving ultrasonic technology, they must be coated with a thermoplastic coating. In countries such as Germany or France, for a material to be considered a mono-material and thus enter an orderly recycling loop, it must not contain more than 5% foreign material. In countries such as the USA or Sweden, currently even more generous limits apply, but many large and internationally active companies are guided by the 5% for the sake of simplicity. It goes without saying that the coating must be easily detachable from the paper during the recycling process.
Wide range of materials for almost all requirements The extensive range of banding materials from ATS not only covers a huge breadth of applications from unitizing for logistical purposes to high-quality printed sales packaging, but also meets many environmental compatibility requirements. Examples include paper that is coated on one side, partially coated and thus only at the welding point, or FSC-certified. ATS also invests heavily in the development of increasing tear strength, paper is suitable as a full substitute for plastic in more and more applications.
When will you replace your conventional packaging with ecologically sound banding with ATS? Visit ats-tanner.com and discover application examples and case studies from your industry.
Consumer impact MACHINERY
Tilda is also supporting vocational training for students in hospitality and inspiring the next generation of talented chefs in partnership with Cyrus Todiwala, OBE. Jon Calland, Head of Sustainability & External Affairs at Tilda, comments: “As the climate crisis worsens, it is the responsibility of industry to act, and influence change. This is about more than responding to consumers’ sustainability concerns and customer objectives, it is ultimately about creating a responsible and resilient business.
“ I hope that we can encourage more businesses to consider their impacts on the planet and people ” “By launching the Tilda® Impact Report 2021 and being honest and transparent about our challenges, I hope that we can encourage more businesses to consider their impacts on the planet and people, whilst supporting our trade customers to play their part. “We understand the importance of taking responsibility for our impacts across the value chain, specifically looking at the journey from paddy to plate – from the farmers who grow our rice to what happens to our packaging after our products are used.
Our commitments and progress
And we have seized the opportunity presented by the pandemic to drive positive change – from putting employee first flexing to meet customer demands to We want tosafety be honest andand transparent about our progress and challenges as support we work to communities, sustaining farmer increasing our to achieve our commitments . This section maintaining sets out ourlivelihoods, approach across our three main global rice chains and supporting priorities and our contribution to communities . recycling. “We’ve made Responsible sourcing
great headway, but there is still so much to page 24 achieve. By opening up the conversation about our impacts Reducing the impact and publicly sharing our commitments, we will continue to of our manufacturing page 30 work with our partners to achieve our ultimate ambition of Reducing the impact becoming one of the page most inspiring and responsible rice of our packaging 48 producers in the world.” Making a positive impact on communities
page 56
To read the Tilda® Impact Report 2021 in full, please visit: www.tilda.com/about-us/corporate-social-responsibility/impact-report/
Tilda Impact Report 2021
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SPONSORED Consumer impact
MONTA
RETEC 831 ith Film made w ylene, polyprop 100% PIR lastic. no virgin p
RETHINKING
WASTE WITHOUT COMPROMISE
www.monta.de/en
monta reTec 831 - the sustainable & strong packaging tape The calls for increased use of plastic recyclate coupled with the progress in recycling technologies gave German tape manufacturer monta Klebebandwerk GmbH the impulse to develop a sustainable self-adhesive tape based on recycled film. Industrial plastic waste that was previously discarded is given a new life by processing it into 100 percent post-industrial recycled polypropylene at the film manufacturer’s facility. This carrier material is then coated with natural rubber adhesive at the monta plant, creating the new self-adhesive tape monta reTec 831. The raw materials utilized for monta reTec 831 have a carbon footprint that is 33% lower than that of conventional BOPP tape. Designed to securely seal medium heavy to heavy cardboard boxes, this sustainable tape offers the same technical performance as its standard BOPP counterpart. It can handle challenging deep-freeze applications and difficult surfaces like testliners. Application with hand dispensers and automated packaging lines are both possible.
Less is more Responsible use of resources is important when selecting raw materials, but also when applying packaging tape. monta tapes with natural rubber adhesive usually seal the box with just one layer. If tapes must be applied in multiple layers to achieve a reliable seal, material consumption increases significantly. Product range grows greener With a size of 30 billion square meters annually, the packaging tape market has huge potential for “green” alternatives. In 2019 “monta Greenline” was launched with the introduction of monta biopack®, a 90% bio-based packaging tape. monta reTec 831 is an additional high-performance tape, expanding monta’s Greenline portfolio. monta has gone one step further and has been compensating CO2 emissions for all monta Greenline tapes since August 2021: By supporting recognised climate protection projects that are accredited to international standards, monta now offers a “climate-neutral” product range.
Consumer impact
ZENTEN (ZBG)
Tapping into sustainable magic Creating tools that offer ‘plumbing magic’ has been a regular feature at ZBG, (Zenten Bernhard Groten) for some time now, and it is all down to an unassuming British plumber by the name of Darren Chalkly. Since 2018 Darren has been working with Zenten on their new range of innovative construction industry tools. Prior to Darren’s involvement in the company, Zenten had been successfully manufacturing high quality equivalents to traditional plumbing tools. Darren is the Business Development Director at Zenten. Since ZBG discovered his unique talent, Darren has been busy creating time-saving and super- efficient plumbing tools. The success of these products has resulted in him moving to the US where a new production and distribution facility is scheduled to open in 2022. Here his innovative touch will no doubt continue to proliferate, as will his passion for sustainable packaging! Philip Yorke reports.
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Consumer impact
Darren Chalkly
Having interviewed Darren Chalkly recently and been struck by his infectious enthusiasm, I was not only impressed by his ability to bring a great deal to the table, but also by his unabashed and self-effacing modesty, which was at no time diminished during our conversation! As an experienced MD with demonstrable success in operations management and planning, Darren decided that ZBG’s products’ excellence and its commitment to sustainability, was an attractive proposition. ZBG is recognised globally for its consistently high quality and innovative design capabilities. This skill has resulted in it being represented throughout the world’s most important markets. The company was founded in 1966 when a young German engineer by the name of Bernhard Groten established a small workshop in Irun, Spain where he manufactured manually operated drills and precision sharpening machines. Today that small workshop covers more than 5,000 square metres and produces over one million items every year. “At Zenten we create customised tools that set the standards in the building trade for product excellence. Our on-going success has meant that in January 2022 I will be operating from a new state-of-the-art facility in California, USA, where a constant stream of new, innovative products for the plumbing trade will be designed and marketed” said Darren.
He added, “Of course team work is an important factor in anyone’s success story and I owe much to Regina Valenciaga and Zigor Vazquez of Zenten, as well as the talents of the Morisketti design team in Irun, Spain” “As for me, creating tools that outperform others on the market, comes as a natural thought process. Perhaps this is because I grew up in the building trade and worked for 25 years as a plumber before getting into product design. I also believe that sustainable packaging is key to our success and today we are using 3-4 layers of special cardboard to package each item. In addition, we have even adapted our products to fit our new recyclable packaging! I would say that recently we have had more exposure through our advanced packaging design than we have from our new tools! We will be the first of our kind in the USA, and I look forward to receiving a positive reception once the trade there see the many unique advantages offered by our high-quality range of tools”. Here at SPN, we believe that the success of Zenten is well deserved and to be applauded. The company’s commitment to the use of sustainable materials throughout its manufacturing processes and packaging, sets a fine example of what can be achieved to others in the building trade. The Zenten philosophy is based upon ‘technological excellence and innovative management’. This would seem to us to be an unquestionably sound formula for their continuing global success.
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