Issue 21:1 - February 2021
SUSTAINABLE
PACKAGING NEWS
Taking the lead in sustainability
Food for thought Food packaging can be a very controversial issue. SPN looks at the benefits of this and it’s impact on the environment
Digimarc
The company’s commitment towards a sustainable, circular economy with the ‘Holy Grail 2.0’ project
Luxury packaging Bioplastics
Adding less to achieve more Tetra Pak has developed a formula that allows it to make more products, by adding less!
Recyclable mono-material BOPE Packaging solution. Ethy-Lyte™, a breakthrough bi-axially oriented, polyethylene (BOPE) range of films for lamination with PE sealants, creating fully recyclable mono-PE packaging.
Ethy-Lyte™ REVOLUTION IN RECYCLABLE PACKAGING Making the world more sustainable
To find out more
contact us at Ethy-Lyte@jindalfilms.com Or visit our website
www.jindalfilms.com/ethy-lyte-recyclable-packaging-solution
WELCOME TO SPN MAGAZINE
Welcome to Since our last issue we have seen a clear focus on planning ahead for when the global vaccination programmes return us to a modicum of normality. However, despite the on-going lock-downs and restrictions, the most up-todate analysis shows that packaging companies are managing to stay ahead of the game and are well prepared for the forthcoming plastic packaging legislation. At SPN, we are dedicated to helping you to become better equipped to meet any changing market forces and in particular the latest Covid 19 situation. With the pandemic mutating and spreading faster than ever, it is a race against time to get the world immunised in order to put the global pandemic behind us. In this issue we provide you with some valuable insights into how to best deal with the on-going Corvid 19 fall-out. This is in addition to what is trending and who is breaking new ground in the quest for increased sustainability and the circular economy. There is also a special focus on how retailers both large and small are shining a light on their innovative marketing techniques. These are designed not only to meet their customer’s growing expectations, but to exceed them, and in the process offer some interesting lessons for us all. Today SPN is leading the way in promoting sustainability and resource efficiency and we are delighted at the response we’ve had from our readers since our launch in 2020. Many manufacturers have already benefited from the various strategies featured in our pages. In view of this, please let us know if you have any news items of your own that you would like shared on the SPN platform. We look forward to hearing from you!
Philip Yorke ( Editor )
SUSTAINABLE
PACKAGING NEWS Feb 2021 Issue 21:1 - February 2021
SUSTAINABLE
PACKAGING NEWS
Taking the lead in sustainability
Food for thought Food packaging can be a very controversial issue. SPN looks at the benefits of this and it’s impact on the environment
Digimarc
The company’s commitment towards a sustainable, circular economy with the ‘Holy Grail 2.0’ project
Luxury packaging Bioplastics
Adding less to achieve more Tetra Pak has developed a formula that allows it to make more products, by adding less!
Director Editor Writer Designer
Kevin Gambrill Philip Yorke Emily Dimas Dom Thorby
linkedin.com/company/ sustainable-packaging-news/
news_packaging
spnews.com SUSTAINABLE PACKAGING NEWS
3
CONTENTS
Contents TOPICS
RESOURCE EFFICIENCY 20 Adding less - to achieve more RETAIL ROUND-UP 24 A new recyclability topic from SPN FOOD PACKAGING 28 Food for thought SYNERLINK 35 Sustainability’s vital link
REGULAR FEATURES SUPPLY-CHAIN SLEUTHS 6 The latest developments in supply chain management
SPN SPIN DOCTORS 10 Covid 3-step survival plan DIGITAL DIGEST 14 The rapid growth of digital print 17 Digimarc - ‘Holy Grail 2.0’ project
BIOPLASTICS 38 All set for natural degradability PLASTIC PACKAGING 44 Plastic innovation SEALED AIR 48 Q & A with Ed Roberts CORRUGATED PACKAGING 34 Corrugated board LUXURY PACKAGING 36 At its finest! RECYCLABILITY 58 Bottles V Cartons 62 The race to ensure a better future
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Issue 1 Sep 2020
CONTENTS
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36
58 34
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SUPPLY-CHAIN SLEUTHS
Supply-chain Sleuths
Going creative with Click & Collect! The rapidly changing face of modern supply chain logistics, is due to a variety of reasons ranging from the Covid Pandemic to digitalisation and the drive for a greener world. These seismic forces have impacted on companies throughout their international supply chains and beyond. Increased use of robotics has also played a big role in the way goods are packed and transported. Netherlandsbased company Schoeller Allibert says it has seen an upsurge in demand for its returnable transit packaging (RTP), as brands and retailers face increasing pressure to meet Net Zero carbon targets and storage warehouses introduce new advanced technologies. The shift in emphasis has caused Schoeller to reshape its product range, including the recently launched Maxinest® E-tail and Maxinest Evo® family of products, which includes new and upgraded versions of its Maxinest container for the grocery and supermarket retail sector. The new range of products includes features that enhance performance in automated warehouses, as well as Click & Collect and home delivery environments. Jon Walkington, Retail and Systems Integrator Sales Director at Schoeller Allibert UK, commented: “As part of the UK’s commitment to reducing the impact of climate change and making British industry carbon neutral, the Net Zero drive is shaping how day-to-day operations are carried out. With 2050 being the current target to achieve Net Zero and many calling for action sooner, it is likely to be a key industry driver for some time to come.
“ the Net Zero drive is shaping how day-to-day operations are carried out ” 6 SUSTAINABLE PACKAGING NEWS
“Very early on, brands, packaging and retailers understood that reaching carbon neutrality couldn’t be done purely by changing products, ingredients and components, global supply chains are too complex for that. Instead, we look further up the process to find additional sustainability gains in terms of efficiency and reduction of waste. When sustainability needs to be demonstrated at every single level of the manufacturing and supply process, brands look to tighten how they move, handle and store goods and ingredients. Naturally, plastic RTP is perhaps the most robust way of reducing waste through handling, which I believe is why we are seeing such a strong up-turn in use.
Net Zero means adapt and adopt By adopting RTP practices and adapting to new market forces it is possible to increase efficiency via streamlined logistics, as Chris Walkington said, “It’s clear that as brands prepare to adopt and implement Net Zero principles, supply chains will continue to see major operational shifts. After a challenging few months, sustainability and recyclability is very much back in focus. It’s now a question of finding new areas for efficiency, and for many businesses, the answer lies in efficient goods handling and streamlined logistics. What will prove absolutely crucial is momentum, how we can continue to create change in increasingly complex global supply chains. Plastic RTP is one of the ways that this is being accomplished, but we expect to see continued innovation to further support these changes.”
SUPPLY-CHAIN SLEUTHS
Mentioning plastic and defeating climate change in the same sentence might seem like an oxymoron, but one British company is determined to demonstrate that there are alternatives to the traditional materials, particularly when it comes to the ubiquitous wooden pallet.
Plastic pallets gaining ground Goplasticpallets.com, which supplies an alternative solution to traditional wooden products, has widened its own plastic pallet and box recycling scheme to include products made by other companies. Since launching the industry’s first plastic pallet recycling scheme in February 2019, the company has gained support from customers nationwide, allowing the company to recycle more than 420 tonnes of plastic waste from used plastic pallets and boxes. Jim Hardisty, Managing Director, said: ”We promise our customers that when they buy from us, we will collect and recycle each and every plastic pallet and box we supply at the end of their long working life, or when they no longer have need for them, but we’ve come across customers who have old plastic pallets and boxes from other suppliers which they have no need for, but no easy way to dispose of them, as they were never offered the option to join a recycling scheme when they bought the products. “This is why we’ve decided to take more responsibility, where others are not, and towiden our recycling scheme. You could say we’re on a mission to clean up the nation of old or unused plastic pallets and boxes. Customers currently signed up to our plastic pallet recycling scheme benefit in two ways; they get to further their commitment to reducing plastic waste, but as used plastic pallets and boxes have an inherent value, they very often get a return in rebate too.
“ the 420+ tonnes of plastic we have recycled to date is enough material to make more than 76,000 of our popular Cabka-IPS 110 PR nestable plastic pallets” “To put our offering into perspective, the 420+ tonnes of plastic we have recycled to date is enough material to make more than 76,000 of our popular Cabka-IPS 110 PR nestable plastic pallets. It’s an achievement we are immensely proud of, particularly given the challenging times we are facing.” Hardisty says that 96% of the long-life, reusable plastic pallets and pallet boxes which the company makes are themselves created using entirely recycled materials. The advocates for this technology point out that wooden pallets also have an effect on the environment, plus many are carrying toxins when treated to eliminate pests, and with the ISPM15 regulation about to hit UK companies, plastic for many will prove a viable alternative. It is very reassuring to see that companies both large and small are steadily moving towards their Net Zero carbon targets. From the constant market monitoring conducted by SPN, we can see that every aspect of supply chain management is moving forward in tandem with an increased drive for greater sustainability and production efficiency. This bodes well for a greener future for us all.
“ companies both large and small are steadily moving towards their Net Zero carbon targets ” SUSTAINABLE PACKAGING NEWS
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SUPPLY-CHAIN SLEUTHS
Re-writing e-commerce logistics The pandemic has resulted in a deluge of activity and new logistic’s start-ups. With e-commerce supply chains still recovering from the devastation created by Covid in 2020, The year ahead offers little respite. Emma Cosgrove of Emmacos made some interesting observations in a recent report published at the end of January, which act as an interesting footnote to the current supply-chain fragmentation. “With societal and supply chain shifts here to stay, the major parcel carriers have confirmed suspicions that peak surcharges will continue beyond the forthcoming holiday season. The past is a peak season in which capacity was scarce, communication incomplete, volume unprecedented and service erratic. The present is the ubiquity of same-day logistics start-ups and their integration into retailers’ e-commerce options. The future offers a new dynamic between shippers and carriers that could benefit but a select few. During the pandemic, Instacart, Postmates, Roadie, Shipt and others have moved into new roles, in many cases integrating into retailers’ parcel portfolios as an alternative to traditional carriers. In a world where parcel carriers choose which volume they carry, some shippers will win capacity and some will lose. Skill and investment will determine the winners.
For further information and the full report visit: emmacosgrove@emmacos.com
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SPN SPIN DOCTORS
SPN Spin Doctors The latest Spin from SPN
The digital driving force
The Covid-19 pandemic and the economic crisis it has created are the major factors shaping the print and printed packaging sectors across the world. With human behaviour irrevocably changed by the virus, the analogue to digital print transformation-trend is accelerating and time-to-market and response are becoming increasingly important. This is according to a revealing new study from Smithers, extracts of which are highlighted here. Philip Yorke reports.
10 SUSTAINABLE PACKAGING NEWS
SPN SPIN DOCTORS
According to the latest Smithers report, the global print market was worth a total of $743.4 billion last year. Today the industry is redefining itself as the importance of publications and graphics diminishes, thus pushing printing companies more towards packaging print. Taking over is the use of smarter, more digitised, short-run printing that is more flexible and more cost efficient. It is predicted that by 2030 the digital packaging sector will have grown significantly, achieving a 23.1% share of value and 6.3% of print volume. This value is the prize for companies adopting digital technology. To support this growth, suppliers are continuing to develop improved print machinery and consumables to compete against the old analogue methods in mainstream markets.
“ by 2030 the digital packaging sector will have grown significantly “
Major re-definition With global volumes down in 2020 due to the pandemic and the consequent recession, the only sectors showing any resilience are those of packaging and label printing, whilst publications, advertising and graphic printing have been the most negatively affected. A revival of normal business activity in 2021 is expected to see the market rebound slightly to reach $752.8 billion. However, much of the volume lost in 2020 will not return. According to Smithers, value growth will return to push the market to $846 billion by 2030, as it undergoes a profound redefinition of its operations and priorities. Part of that redefinition will be reflected in print substrates, with total volume falling from 1.95 trillion square metres in 2019, to 1.85 trillion square metres forecast in 2030. Overall tonnage will increase from 251.7 million tonnes to 264.4 million tonnes over the same period, as heavier packaging grades are employed and graphic paper volumes decline.
SUSTAINABLE PACKAGING NEWS
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SPN SPIN DOCTORS
Evolving ‘AI’ By the year 2030, multiple manual production and print administration tasks will be handled by Artificially Intelligent (AI) robots with vision systems handling quality control. Machine learning will be built in, allowing machines to take on more decisions about print or finishing quality. Artificial intelligence will be more prevalent in print from creation to delivery, in order to minimise waste and its environmental impact. This will lead ultimately to the evolution of the hyper-autonomous press. By the end of the decade, new equipment builds will be highly autonomous with operator involvement reduced to specific problem-solving actions.
Enabling simplified production In the wake of Covid-19 and beyond, there will be different supply chains for many products, with much manufacturing re-shoring back into Western Europe and North America. Simplifying production methods will be one enabler, with new printing methods incorporated to allow cost effective short run, fast turnaround.
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To safeguard against future shortages and supply chain disruption, buyers will opt for faster time-to-market for many products. Improvements in response time will take place as print companies adjust to the “AmazonEffect” and expectations of same-day or next-day delivery. In labels and packaging, some brands will bring production in-house, or invite a partners to cooperate via through-the-wall operations. This will drive further incorporation of digital and Industry 4.0 concepts to simplify workflow, artwork generation, print production in combination with online specification and ordering. The new report also predicts that the economic shock of the pandemic for print service providers (PSPs), will lead to bankruptcies and fewer operational sites as well as more mergers and acquisitions. Companies that do emerge from the pandemic will need to focus on cost, responsiveness and digitisation for continued survival. PSPs will also need to expand the products and services they provide. Social distancing signage and personal protective equipment (PPE) emerged as a means for expansion in 2020 and the trend toward industrial and functional decoration will continue.
For further information visit www.smithers.com
SPN SPIN DOCTORS
Get on your bike… and recycle The April 2022 legislation is set to significantly boost recycling. The UK government has published draft legislation and a policy paper on the ‘Introduction of a new plastic packaging tax’. This will take effect from April 2022. The tax is likely to have the biggest impact on the waste and recycling sector since the landfill tax was introduced. By contrast it offers indirect taxation, rather than just the PRN system, in order to boost recycling. The government is now publishing a draft of the legislation for technical consultation which sets out the key features of the new tax”. It is anticipated that as a result of the tax there will be a significant increase in the amount of plastic packaging with greater than 30% of it recycled. The HMRC policy paper states: “Recycled plastic has a carbon footprint that can be up to four times lower than that of virgin plastic. The policy may also help to divert plastics from landfill or incineration, and drive new recycling technologies. Key features include a £200 per tonne tax rate for packaging with less than 30% recycled plastic and there will be an exemption for businesses which manufacture and/or import less than 10 tonnes of plastic packaging in any 12-month period. In addition the scope of the tax will depend upon the definition of the type of taxable product and recycled content. Furthermore, there will be exemption for producers and importers of small quantities of plastic packaging who will be liable to pay the tax and therefore need to register with HMRC as to how any tax may be collected, recovered and enforced
However, the tax will not be chargeable on plastic packaging which has 30% or more recycled plastic content and is made of multiple materials of which plastic is not proportionately the heaviest when measured by weight, or, it is manufactured or imported for use as immediate packaging of licensed human medicines. This could be in use as transport packaging to import products into the UK; or is exported, filled or unfilled, unless it is in use as transport packaging to export products out of the UK.
“ The tax will provide a clear economic incentive for businesses “ Greater incentive The Tax has been proposed by the Treasury who explained that the measure is not expected to have any significant macro-economic impacts. “The tax will provide a clear economic incentive for businesses to use recycled material in plastic packaging, which will create greater demand for this material and in turn stimulate increased levels of recycling and collection of plastic waste, diverting it away from landfill or incineration.” Any incentive that stimulates a greater commitment to sustainability is to be welcomed, even if it does mean a knock-on cost to the taxpayer. However this can easily be balanced by the savings in energy and greater production efficiency at all levels that are being achieved within the packaging industry.
SUSTAINABLE PACKAGING NEWS
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DIGITAL DIGEST
Digital Digest
New digital disciplines ‘just right’ The rapid growth and success of digital print are prompting brands to experiment with ground-breaking marketing projects. The result has been improved brand loyalty from consumers, as well as creating innovative business models that satisfy new regulatory demands. According to the latest Smithers report (The Future of Digital Print for Packaging 2022) digitally printed labels and packaging was worth $13.4 billion in 2017. While the label sector has been the early adopter and is mature in some regions there is very strong growth in corrugated, carton, flexibles and direct-to-shape, with further development in metal printing. By 2022, the rapidly expanding digital (inkjet and toner) packaging market will grow by almost 13% annually to exceed $22.0 billion. The market for digital print is expanding at over 15% for all formats with the exception of labels where it is already well-established. Digital print platforms are opening up a whole world of possibilities for boosting emotional engagement with a consumer, and creating new revenue streams. This is allowing brands, design agencies and retailers to become more creative, with many launching innovative campaigns to enhance approval ratings; while other businesses across the value chain can evolve new, lucrative business models. Smithers has identified the key drivers that are making digital print such an attractive option.
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Short-run revolution As with most print products, the average run length for packaging jobs is decreasing. Analogue processes are well suited to minimise the costs of long and medium runs which used to account for the bulk of pack and label work. This situation is changing with more fragmentation and versioning, as new small businesses and boutique retailers join the market and thus accelerating the short-run revolution. There are many more short runs with any high prepress and finishing costs often added as a “one-off” charge. The ability for digital to produce short runs economically has significantly changed the label sector and it will do so for other parts of the packaging market. Eliminating the minimum order quantity will open high-quality packaging and labels to many more players, and grow the overall market dramatically. Digital is well suited to short run production, as there are no plate costs. Using online web-to-pack portals is reducing administration and prepress costs for producing press-ready artwork and will further boost the acceptance of digital labels and packaging in the future.
DIGITAL DIGEST
Increasing consumer engagement Today digital print represents a powerful tool for engagement and it has a lot to thank the Coca-Cola Corporation for. The well-known “Share a Coke With…” series of marketing campaigns brought the capability of digital printing into the mainstream for brands, designers, and converters. The main campaign was a mass-customisation versioning of PET bottle labels, supplemented by one-off specific names printed ondemand for glass hobble skirt bottle packs via a website, and more generic versioning of metal cans. It was the biggest series of marketing campaigns run by Coca-Cola, putting the packaging as the message. The packaging design of form, function and graphics has always been important, but the Coca-Cola campaigns showed that the pack can also be a critical part of the customer experience. Packaging is being specifically used as a component of the brand strategy to win customer approval, as consumers spend more time interacting with a product after it has been bought. There were many copy-cat campaigns brought to market with names, places or sports teams featuring on the pack. Many companies put forenames onto their packs, for instance Nutella and Marmite, while Oreo cookies ran a campaign to colour in the pack design and get the pack sent direct to the buyer.
“The dinner’s in the dog” Global FMCG brands are using digital print to increase their emotional engagement with consumers and potential customers in order to boost brand status. Purina (a Nestlé pet food brand) sells Just Right, a premium range of personalised dog food. The pack has the dog’s name and picture, the owner’s name and the Just Right logo on it. The food is formulated for the dog, taking the breed, size, age, activity and various other factors into account. The company uses the information about the dog they have been given to satisfy the owner’s desire to deliver an individualised experience for the pet. This combination of owner, brand and dog is a very powerful engagement.
Courtesy of Smithers and Nestle
Personalising the product by identifying and matching the consumer preferences has proved to be a major success for Nestle. This success is likely to stimulate a growing trend for greater consumer involvement and not only FMCG packaging but also for any product where there is either consumer or business diversity.
SUSTAINABLE PACKAGING NEWS
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DIGITAL DIGEST
Productivity to die for Back in North America, Canada’s Clear Tech Industries is now able to die-cut different size labels from the same raw material. This is thanks to its installation of the latest digital technology from Lemorau. The EBRM+ semi-rotary finishing system has been developed by the Portuguese manufacturer Lemorau. Arrow Systems is the distributor for these systems in both the US and Canada and it also represents Anytron digital printing systems. The addition of the Lemorau EBRM+ allows this Canadian company the ability to die-cut different size labels from the same raw material. Previously it has been printing on pre-cut roll labels, consequently increasing costs and inventory burden. The ability to cut its own materials helps to save money on printed labels and provides flexibility to change sizes as needed.
“ a relatively small investment in new digital technology can make a big difference ”
Shaan Patel, business development manager at Arrow Systems, said, ‘One of the main benefits of having your own label cutter is that it gives you a lot more flexibility when it comes to ordering label materials. When you are printing on pre-cut labels you have to keep an inventory of each size that you are planning on printing. This becomes a logistical nightmare for a lot of companies, and a small label cutter like the EBRM can solve that in no time.’ Karen Madill, label systems operator at the ClearTech plant in Port Coquitlam, Canada added, ‘The Any-002 has also saved us a lot of time and money on our label requirements, whilst also giving us the flexibility to change our designs as required to keep with the latest CHS regulations. Lemorau’s EBRM+ is a good example of how a relatively small investment in new digital technology can make a big difference in terms of productivity and efficiency, all of which makes a significant contribution to resource efficiency and the circular economy.
The compact EBRM+ digital labelling machine
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DIGITAL DIGEST
Making today’s mark on circularity Digimarc is a global leader in the field of digital watermarking. The company’s unrivalled commitment towards a sustainable, circular economy is exemplified by its participation in the ‘Holy Grail 2.0’ project, described here in this special SPN feature. It is generally understood that currently far too much plastic waste is going into landfill, in fact today only 9% of global plastic waste is recycled. This is according to a 2019 study published in the peer-reviewed journal ‘Science Advances’. Furthermore, Europe’s, ‘Euromonitor’ calculates that an estimated 2.7 trillion units of plastic based packaging will be in global circulation by 2022. Euromonitor also states that huge volumes of materials will not be contributing to the circular economy. This equates to the potential loss of huge resources, as well as lost value, and a missed opportunity for the industry to meet its recycled content goals. This is simply a cost that the industry cannot afford. Digimarc develops high-tech solutions featuring digital watermarks in order to increase the recyclability of plastics and improve the sustainability and functionality of today’s diverse packaging portfolios. As companies look to engage more with consumers, digital watermarking offers a unique interaction with the product and ultimately the brand. Almost imperceptible to the naked eye, but eminently readable by smart phones and tablets, the Digimarc barcodes make the package itself the passport to sustainability.
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DIGITAL DIGEST
Intelligent packaging through Digimarc Barcode
Looks like this Sustainability goals, recyclability information, health information, corporate values and much more, can all be conveyed to consumers through the company’s advanced Digimarc barcodes. This technology allows brands to sell much more than just products, it enables a powerful consumer experience that helps to build brand loyalty and brand equity. But the power of the barcode doesn’t end with consumers. Once in the recycling packaging with a barcode it can be efficiently and accurately separated, thus significantly increasing the current levels of waste recovery. Today, there is virtually unlimited data associated with the packaged object, for example, individual manufacturer, resin type and the components that make up multi-layer packaging. As a result, the objects become the ‘Internet of Things’ or IoT-ready objects, and it is now possible to address many current issues in sorting challenges such as carbon-black plastics and flexible pouches.
The ‘Holy Grail 2.0’ initiative Digimarc has developed a powerful digital identity, with its Digimarc Barcode , which delivers more data, offers greater capabilities and enables easier automatic identification of product packaging and other media.
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Performs like this This is especially true when compared with other common visual elements, such as a UPC or QR code. However, there is now a truly exciting project that pulls the supply chain together, and one that clearly demonstrates the power of Digimarc Barcode in today’s sophisticated recycling systems. Facilitated by the European Brands Association, ‘HolyGrail 2.0’ is a cross-value chain-collaborative initiative that aims to speed the transition to a circular economy for plastics, by increasing the quantity and quality of recyclable material through identification. Built on its long history as a pioneer and world leader in digital watermarking technology, Digimarc Barcode enables better detection and sorting as well as improving the economics and efficiencies of the recycling value-chain and supply chains for global retailers and their brands. Digimarc’s strategist for sustainability and recycling, Larry Logan, has enthusiastically described to SPN the enormous opportunities that Digimarc Barcode offers the packaging industry. “As part of the high-profile HolyGrail 2.0 project focused on pioneering the use of digital watermarks for a circular economy, we will better enable companies to reach their recycling and recycledcontent goals. ”
DIGITAL DIGEST
Logan said. “We’re proud to support Procter & Gamble, Danone, Nestlé, PepsiCo and other renowned consumer brands to help meet their ambitious, but essential sustainability targets.” Sustainability leaders and HolyGrail 2.0 members recently set out to demonstrate the recovery advantages that Digimarc technology has to offer. This includes, more precise and accurate sorting (e.g., food grade v. non-food grade), less contamination, and better data to help companies meet their voluntary recovery goals and regulatory mandates.
Increasing global interest Digimarc continues to attract increased global interest among the industry’s foremost leaders for its innovative approach to optimising packaging for more effective recycling outcomes. Digimarc is a member of several key groups including the Sustainable Packaging Coalition, European and U.S. Plastics Pacts, Association of Plastic Recyclers and many more influential sustainability and trade organisations, in addition to being signatories to the Ellen MacArthur Foundation’s ‘Global Commitment’ project.
Full life-cycle sustainability Digimarc told SPN that to achieve optimal sustainability, business operations today must significantly reduce waste wherever possible. Digimarc digital identities help manufacturers to reduce waste during production due to issues such as labelling errors and mismatched parts. Furthermore, limiting waste in processes and workflows throughout the supply chain supports greater operational sustainability. Digimarc technology delivers item-level identification and serialisation that enables global supply chain leaders to pinpoint the precise location of products anywhere, as well as providing better management of recalls, thus boosting efficiency across a complex global network of distributors. Global industry leaders recognise that Digimarc is at the forefront of developing new technologies to reduce waste, increase traceability and improving recyclability across the board. Digimarc’s mission is to deliver digital identities that support more sustainable packaging and a circular economy for a less wasteful and more profitable future for all.
“ Global industry leaders recognise that Digimarc is at the forefront of developing new technologies to reduce waste ” “We are excited about the potential impact Digimarc could have on recycling,” said Robert Flores, vice president for sustainability at Berry Global, itself a global leader in plastic packaging. In addition, manufacturers of advanced sorting technology products also recognise the value of digital watermarks as the preferred route to the more efficient recovery of materials. “We look forward to continuing our work with Digimarc in the HolyGrail 2.0 initiative, toward bringing to market the enormous potential of the technology for recycling sortation,” commented Oliver Lambertz, vice president and head of business development at TOMRA, a leading supplier of hardware for materials recovery facilities. Those interested in learning more, or joining the HolyGrail 2.0 consortium can visit: https://www.aim.be/priorities/digital-watermarks/
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RESOURCE EFFICIENCY
Adding less - to achieve more In the global quest for greater resource efficiency, Tetra Pak has developed a formula that allows it to make more products, by adding less! Thanks to new research revealed recently, its Juices, Nectars and Still drinks are produced using 50% less water and around 70% less energy than previously. Today the company is leading the field in the global drive for greater resource efficiency as Philip Yorke reports. Society is changing rapidly, and today’s consumers have high expectations of how businesses should behave in the light of so many recent and dramatic geo-physical developments. It therefore follows that companies that lead the way on key issues such as sustainability, equality and resource efficiency are gaining greater consumer respect and increasing their customer base - and in the longer term their profits. The global warming crisis has created a clear focus on individual actions, where consumers express their views by making considered and actionable everyday choices. This can influence consumer packaging choices and which type of juice they buy as customers survey the aisles of their local supermarkets. It is a fact that today more than ever, consumers are making choices that represent much more than just a shopping list of products and services. They want brands to operate in a way that’s sustainable and that can result in positive change. If a business does not offer that, it can lead to dissatisfaction with the brand and even to a change in brand loyalty.
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Meeting new expectations Innovation today has to meet new customer expectations that are more focused on protecting our planet’s resources. For the Food & Beverage industry, it’s these changing consumer expectations that make an innovation like Tetra Pak’s new low energy, juices, nectar and still drinks an industry game-changer. Through a radical new approach to production with sustainability at its core, Tetra Pak are able to offer drinks and beverage producers a tool that helps them to meet their key objectives. These can include considerations such as significantly lowering operating costs and making everyday grocery items like juice drinks, meet eco-expectations.
“ The result is a boost in brand trust ” That way a brand and its consumers can jointly contribute to a more sustainable world. The result is a boost in brand trust that’s underpinned by a much more efficient operation.
RESOURCE EFFICIENCY
Tetra Pak’s new JNSD (Juices, Nectar and Still Drinks) line is a first-of-its-kind for the industry. It completely reimagines how we process these products by looking at them through a sustainability lens. The result is a manufacturing line that is cheaper to operate and meets key sustainability objectives like decreasing water consumption by up to 50% and lowering energy consumption by up to 70%, depending on the production scenario. Around the world, water is scarce. The Food & Beverage industry has repeatedly found itself in the spotlight for the amount of water that its production processes consume. Furthermore, high energy usage, is not only bad for the bottom line but also at odds with the fact that our world urgently needs to reduce its overall energy consumption to reduce the impact of climate change.
Ingeniously simple Across the whole supply chain of the drinks industry, the public demand an increase in the sustainability of energy and water use across production, packing and transport. It’s often said that what’s complicated is rarely useful and what’s useful is rarely complicated, and in the case of the new JNSD technology from Tetra Pak the ingenious design is rooted in its simplicity. Taking an original, cutting-edge approach to the processing concept, the new technology essentially strips out unnecessary wasteful elements, and merges existing processing technologies into a streamlined, energy-efficient processing line that combines filtration, UV treatment, Pasteurization and Aseptic Blending into one.
Saving water should be a priority for all manufacturing industries and with countless innovative new processes making production so much more efficient, it is something of which the packaging industry in particular can take full advantage.
Collective solutions All over the world packaging companies are down-gauging, reducing their power and material consumption and producing resource-saving machinery. Furthermore, there are new printing technologies today that use water-based inks, which in turn are controlled by digital screens. Here at SPN it is great to see supply chains working so well together to achieve their common sustainability and resource-efficiency goals. A good example of this is SABIC’s collaboration with Syntegon, Ticinoplast and Plastchim-T which have combined to offer collectively, new sustainability solutions. Stephen Eltink, SABIC’s Business Director for PE in Europe, said, “At SABIC we focus on delivering sustainable solutions and work closely with our customers to help them to achieve their sustainability goals and solve key industry challenges. By working together with our partners, Ticinoplast, Plastchim-T and Syntegon, and by levering our collective innovative expertise, we have been able to introduce new solutions to the market that allows for more sustainable packaging, and this is without any compromise on productivity or consumer convenience”. So it’s well done to all three sustainability-committed companies This kind of close collaboration makes a world of difference and one that we can all benefit from!
SUSTAINABLE PACKAGING NEWS
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RESOURCE EFFICIENCY
“ reducing the amount of waste generated at source, also called prevention, is an important lever for increasing resource efficiency ” Smart, inclusive resource-efficiency Resource efficiency means using the Earth’s limited resources in a sustainable manner whilst minimising impact on the environment. It allows us to create more with less and to deliver greater value with less input. Increasing resource efficiency is a key part of the European Union (EU) strategy for a smart, inclusive and sustainable economy. The EU Roadmap to a Resource Efficient World outlines how we can transform Europe’s economy into a sustainable one by 2050 and it could also be used as a template for the rest of the world. The areas of focus where appropriate actions can make a real difference are nutrition, housing and mobility, the sectors responsible for most environmental impacts from a life cycle and value-chain perspective. Reducing the amount of waste generated at source, also called Prevention, is an important lever for increasing resource efficiency. Prevention is regarded as the highest priority according to the Waste Hierarchy established in the EU Waste Framework Directive. The following areas demonstrate how flexible packaging plays a key role in supporting prevention and resource efficiency at the European level.
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How Resource Efficient are you? IFEU, an independent research organisation, was asked to study two scenarios on primary packaging used in Europe for Fast Moving Consumer Goods (FMCG) excluding beverages: 1) what if all rigid packaging were substituted by flexible packaging and 2) what if all rigid packaging were replaced by flexible packaging. The results of this study updated in 2019 show that in the first scenario – substituting rigid by flexible – the total weight of primary packaging used for non-beverage FMCGs in Europe.
RESOURCE EFFICIENCY
The results of this study show that in the first scenario – substituting rigid by flexible – the total weight of primary packaging used for non-beverage FMCGs in Europe could be reduced by 21 million tonnes per year ( a 70% reduction) and Global Warming Potential (GWP) could be reduced by 33%. The opposite scenario – substituting flexible by rigid – would increase the total GWP of the primary packaging used for non-beverage FMCGs in Europe by about 31%. This is despite the much higher actual recycling rates of rigid packaging. Even if the recycling rate of rigid packaging was raised to 100%, this would still lead to 14% higher GWP. In addition to GWP, the environmental impacts of Abiotic Depletion, which refers to the use of nonrenewable resources, and Use of Water were also assessed, showing similar results in the same order of magnitude.
The study concludes that for packaging the focus should not be on recyclability only but also and foremost on prevention. This can be achieved by a higher use of flexible packaging, which would lead not only to less primary packaging waste, but also to lower carbon footprint and use of resources. Conversely, a focus only on recyclability and achieving recycling targets, which might encourage the substitution of flexible packaging solutions by more easily recyclable rigid packaging, would clearly be detrimental for climate change and resource efficiency. To verify both the approach and the magnitude of these results, a 3rd party LCA agency, Carbotech AG, was asked to review them. Carbotech confirmed the IFEU findings conclusions. These conclusions clarify what resource efficiency really means and highlights the need for greater sustainability in the packaging industry’s day-to-day operations.
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RETAIL ROUND-UP
Retail round-up ( A NEW recyclability topic from SPN )
A new recyclability topic from SPN that looks at the advances in packaging technologies from an FMCG company’s perspective, as well as that of the retailer. In particular it focuses on the market forces that are driving the vital transitions taking place in the industry today. It also recognises the changing relationship between the FMCG companies and the dedicated manufacturers that support and supply them. 24 SUSTAINABLE PACKAGING NEWS
RETAIL ROUND-UP
20 million times more sustainable! Endorsing its reputation as a major driver of change for sustainable and recyclable packaging, Tesco has just announced that it has removed over 20 million pieces of plastic from its Christmas range. This is a welcome gift to the planet and part of a much larger sustainability and recycling programme. The leading supermarket chain said that its own-label crackers are now plastic-free for “the first time” and will offer only non-plastic presents, as well as transitioning to cardboard outer packaging. Christmas crackers have also been made easier to recycle. Tesco chose not to disclose the tonnages of plastic it saved as a result, however a similar initiative in January 2020 saw 20 million pieces of plastic packaging removed from its multipack range. This in turn saved 350 tonnes a year of plastic packaging.
Glittering success n addition, its Christmas lights and Christmas cards will also be stored in recyclable cardboard packaging, and a layer of plastic has been removed from Tesco’s Christmas puddings and sponges. The company says it has also stopped using glitter for all single-use products and packaging, to make wrapping paper, gift bags, cards and crackers easier to recycle. Research conducted by the supermarket chain found that 23% of people will reuse wrapping paper, while 19% will try to be more sustainable by not buying gifts, wrapping or decorations made of plastic.
A billion celebrations Tesco has committed to removing a further one billion pieces of plastic from its own-brand products by the end of 2021. It comes as part of the supermarkets 4R plan for packaging — Remove, Reduce, Reuse, Recycle, which aims to remove plastic wherever possible throughout its operations. The on-going strategy will see Tesco remove “all excess and non-recyclable material from its business”. When turning to the packaging industry for a company that could meet the complex Requirements of Tesco Supermarkets globally, they relied upon Amcor to produce and distribute the vast numbers of Christmas decorations and Christmas Crackers. Amcor CEO told SPN, “We knew that this would be a challenge based upon the wide variety of paper products and the broad global distribution. We were proud to partner with Tesco in order to provide 100% sustainable and recyclable products on this scale” This is yet another example of how the retail sector is working closer than ever with its customers in order to benefit consumers throughout the world and to protect our fragile planet.
Tesco quality director, Sarah Bradbury said: “It is an absolute priority of ours to remove and reduce the amount of plastic in our stores to the minimum and ensure everything we use is recycled and kept out of the environment – Christmas time is no exception and we want to do our bit to help customers have more sustainable celebrations.”
“ It is an absolute priority of ours to remove and reduce the amount of plastic in our stores “ SUSTAINABLE PACKAGING NEWS
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RETAIL ROUND-UP
Choosing plants, not plastic It is not just the FMCG giants that are making big strides to protect our planet but also many eminent charities such as the RSPB, which takes sustainability and environmental protection very seriously indeed. Protecting wildlife and in particular birdlife is central #to their mission and has been since 1889. Recently RSPB team members at Bempton Cliffs, a marine site in the north of England, took action to responsibly reduce, single use plastics that have such a disastrous impact on our oceans. Visitor Operations Manager Scott Smith, takes up the story, “In order to get the project under way, I decided to undertake a “plastics audit” to identify all plastic and non-recyclables in our grab-and-go refreshments facilities and the team started to work on finding alternatives, such as sustainable cutlery and paper straws. Over the last year, the reserve has updated its cold drinks range to eliminate plastic, so that all options are supplied in aluminium cans, glass bottles or recyclable Tetra Pak, including the aptly named “Water in a Box” which is already proving popular as a portable eco-friendly option. “This season, hot drinks will be in served in compostable Vegware cups that use plant materials instead of a plastic lining. It’s this lining in disposable cups that makes them impossible for the reserve to recycle as no local facilities can handle the complex processing needed to separate the lining from the outer paper. Unfortunately, there is a price to pay for sustainability as these alternatives are more expensive, as Scott explained: ‘We’ve taken the decision to ask our customers to share our goal of reducing plastic waste, by increasing the price of our hot drinks by 5p per cup. This helps to cover the cost of these cups and lids. We feel confident our visitors will support our efforts to keep plastic out of our landfills and oceans.”
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Customers bringing their own reusable cups will be rewarded with a 20p discount for helping reduce waste. Re-usable ‘Keep cups’ are also available to purchase at the reserve. ‘Plastic in the food industry is ubiquitous, and often there’s no viable alternative. So we’re on a journey to find the most sustainable options for our visitors and doing what we can to reduce our footprint,” said Site Manager Alison Barratt. “The opportunity to experience a unique wildlife spectacle with nearly half a million seabirds can be inspirational. If we can show our visitors how actions in their daily lives can positively impact nature as a result of their visit here, then together we can all make a difference.’ The RSPB is one of our longest established and best loved nature charities and they are setting a great example to others that rely on visitors throughout the year to visit their sites throughout the UK.
RETAIL ROUND-UP
Recyclables landing on Mars Mars Food and Amcor are ready to launch a recyclable microwavable rice pouch using mono-polypropylene plastic (PP) for its microwavable rice pouches. Working with Amcor, the joint project will bring to market the industry’s first food-safe, mono-material microwavable pouch and to further scale-up the technology across its portfolio during the third quarter of the year. The breakthrough packaging technology will make the pouches for Mars Food’s household brands such as Ben’s Original and Seeds of Change recyclable, where infrastructure already exists. Today the companies are in the final stages of development of the new pouch and the first packs will first be launched in selected European markets by the middle of 2021. The break-through is a result of a three-year development partnership between Mars Food and Amcor.
Building on success Mars Food said it has accelerated the development of the new material through rigorous testing and conducted significant scaled-up tests in its production facilities in the UK. Working in collaboration with Amcor, it then ensured the material developed met all its functional requirements while protecting product quality and safety. Amcor have led the packaging development through their material science and packaging sustainability expertise. This upcoming launch builds on Amcor’s recent AmLite HeatFlex Recyclable breakthrough.
This will be its first application for microwaveable food and the first in a stand-up pouch format. Fiona Dawson, global president, Mars Food, multi-sales and global customers said: “This is a huge step for us towards our 2025 commitment of 100% recyclable, reusable or compostable packaging. We believe in tackling the world’s sustainability challenges together, and through this partnership with Amcor, we will pilot, learn and then scale the volume of recyclable mono-polypropylene pouches across our portfolio.”
New stand-up pouch Michael Zacka, President Amcor Flexibles EMEA, added: “Launching our recyclable retort material in a standup pouch format that meets stringent food safety standards is a challenge, and Mars Food took this journey together with us. It will be a win when their brands deliver this innovation to consumers.” The progress is part of Mars’ Sustainable Packaging Plan, which outlines the business’ commitment and plans to achieve 100% recyclable, compostable or reusable packaging by 2025. The project will also move Amcor closer to achieving its pledge to develop all its packaging to be recyclable or reusable by 2025. We are pleased to note that the big retailers are setting a very good example, when it comes to sustainability, for both the packaging industry and the general public!
“ the big retailers are setting a very good example, when it comes to sustainability “ SUSTAINABLE PACKAGING NEWS
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FOOD PACKAGING
Food
for thought… Food packaging can be a very controversial issue, Emily Dimas explores the benefits of this and its impact on the environment. Cartonboard Pack of the Year has been awarded to leading European packaging manufacturer Coveris in the UK’s flagship industry competition, the UK Packaging Awards. The innovative RecyclaLite skillet is super lightweight, characterised by its design for easy and efficient recycling, 40% plastic reduction and sustainable FSC cartonboard sourcing. Minimising the environmental impact of the pack and product throughout its full lifecycle, RecyclaLite signifies a major development in laminated board packaging. The development of RecyclaLite has been achieved with no compromise to protective, functional or presentation benefits and validated to ensure operational efficiency during manufacture and packing. M&S is the first retailer to switch its sandwich packaging to Recyclalite, its part of their plan to support customers to reduce and recycle packaging. A huge step forward to making the world a greener place!
New advances in line-board packaging Dennis Patterson, Coveris Labels & Board BU President said, “RecyclaLite is a significant advancement in lined board packaging and we are really proud to be awarded Cartonboard Pack of the Year for this achievement. Its development follows collaboration with the supply chain and recycling facilities in our mission to create sustainable and easily recyclable packaging that delivers maximum benefit. The launch of RecyclaLite further highlights the success of partnership between Coveris, Greencore and M&S in leading sustainable packaging innovation for food on the move.”
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Paul Willgoss, Director of Technology for M&S Food, commented: “We are the market leader in food on the move so as we reduce plastic and support customers to recycle, we have a particularly important role to play with our sandwich packaging. Working with Coveris and Greencore, we’ve created an industry-first pack with 40% less plastic that protects the sandwich quality our customers know and trust. This innovative solution enables us to go faster and further with our customers to remove unnecessary plastic – because we know our actions today will help protect our planet tomorrow.” Furthermore, Klöckner Pentaplast (KP), a global leader in recycled content products and high-barrier protective packaging, have told us exclusively that they have chosen its production facility in Beaver, West Virginia, for its multimillion dollar production expansion, adding thermoforming capabilities to further grow their sustainable food tray offer to the North American market.
SPONSORED
Reduce waste with banding. Learn how to replace conventional packaging.
Why banding should also become a standard in food packaging Banding is already a standard in many industries when it comes to reducing packaging material and automating production and packaging processes at the same time.
ats-tanner.com
Banding means “only as much packaging as necessary�. Printed bands made of paper or recyclable film replace plastic bags and cardboard sleeves in many applications. They can take on the role of primary, secondary or tertiary packaging - ideally several roles at once. Bands are printed exclusively with low-migration inks that are also approved for use with food products.
Packaging entirely without plastic Paper sleeves are in many cases an important component of 100% recyclable packaging, which consists of several elements. In the case of cardboard trays, for example, they ensure that the products do not fall out and at the same time take on the role of advertising and information carrier. Partially coated paper sleeves have a foreign material content of significantly less than 5% and therefore also meet strict requirements for monomaterials.
Fewer work steps, fewer machines, less energy consumption Banding machines weld bands using ultrasound. They are extremely reliable and durable. Energy consumption is significantly lower compared to shrink tunnels or other packaging machines. Integrated thermal transfer printers print variable information such as the weight transferred from a scale via an interface, the production date or a barcode on the bands. This makes additional labels superfluous.
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FOOD PACKAGING
“The addition responds to the growing demand for sustainable post-consumer recycled content (PCR) PET packaging solutions in MAP (modified atmosphere packaging) and VSP (vacuum skin packaging) in the fresh protein market.” said Adam Barnett, President of the Food Products Division at KP. This expansion will introduce significant capacity to address the need for highly transparent and sustainable solutions in strategic markets. By increasing capacity for sustainable packaging solutions, we are ensuring that our customer’s sustainability targets can be met for the long term and that we continue to support the circular economy.”
Globally, brand owners and companies are looking for greener packaging solutions. Many companies have publicly made commitments to abandon non-recyclable plastic packaging by 2025. Also, the EU directive banning certain single-use plastic items increases the requirements for recyclability, which further increases the demand for materials like our new eco-barrier paperboard.
Satisfying consumer preferences
The food sector requires barrier solutions that are easy and convenient to recycle, made from mono material, plastic free, compostable and fluoro chemical free. The demands upon the barrier can also be extremely varied in the food sector and currently there is no one perfect solution.
Consumer preferences are driving the use of more sustainable packaging - 52% of European consumers have switched a brand or product because of environmental concerns about how it is packed, according to a study conducted by ProCarton. There is clearly, a growing demand for safe, sustainable, plastic-free and recyclable packaging alternatives to serve and store food. SPN investigates further!
There are also many specialist applications that require complex solutions. Some of these we have solved by considering the packaging design in conjunction with the use of our eco-barrier board. Others we have solved with the application of additional coating technologies to further enhance the present barrier properties.
To meet this demand Metsä Board launched a pioneering plastic-free eco-barrier paperboard with medium barrier properties for grease and moisture resistance - MetsäBoard Prime FBB EB. It is designed to meet the food industry’s needs for sustainable packaging.
“ Many companies have publicly made commitments to abandon non-recyclable plastic packaging by 2025 ”
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FOOD PACKAGING
Metsä Board tells us that they have been at the forefront in the optimisation and lightweighting of paperboards. This evolutionary process will no doubt continue but some of the drivers are likely to shift. The current legislative requirements and environmental goals will change, and the company will need to adapt to reflect those requirements. Metsä Board is continually looking at how it can improve its performance and products to offer better and sustainable solutions to their customers.
This is a huge step for us towards our 2025 commitment of 100% recyclable, reusable or compostable packaging. “We believe in tackling the world’s sustainability challenges together, and through this partnership with Amcor, we will pilot, learn and then scale the volume of recyclable mono-polypropylene pouches across our portfolio.”
Mars Food today announced it will begin to use recyclable mono-polypropylene plastic (PP) for its microwavable rice pouches in 2021. The project will bring to market the industry’s first food-safe, monomaterial microwavable rice pouch. Launching with an initial pilot in the first half of 2021, the business has ambitions to further scale the technology across its portfolio beginning at the back half of the year. Fiona Dawson, Global President, Mars Food, Multisales and Global Customers: “We’re committed to finding more sustainable solutions for our packaging that are food safe without compromising quality.
X- CYCLE™
The complete flexible packaging range of Hatzopoulos S.A. designed for recycling The leading European flexible packaging converter, Hatzopoulos S.A., is dedicated in achieving the goal for Packaging Sustainability. X-CYCLE™ is its complete range of flexible packaging solutions designed for recycling. Thanks to their innovative technology, these packaging films combine recyclability, high-barrier properties, high-performance and many add-on packaging functionalities together. Designed for the Circular Economy, X-CYCLE films guarantee product freshness, packaging aesthetics and compatibility with zippers, spouts, and degassing valves. These solutions can be applied on various existing lines for packaging of a broad range of sensitive products and consumer goods; with the vision for a better future for our planet.
x-cycle.hatzopoulos.gr
FOOD PACKAGING
100% recyclable sachets In addition, FFP Packaging Solutions worked closely with JDM Food Group to produce 100% recyclable sachets that would successfully withstand the demanding hot fill process. FFP are an existing flexible packaging supplier to JDM Food Group, an award-winning food manufacturing company. JDM Food Group use a high volume of sachets in their production and were using a PET/PE mixed polymer material for this which is not recyclable. As a business which takes environmental responsibility seriously, they have collaborated with FFP to help them maintain their achievement of becoming a ‘zero landfill’ site.
FFP have shown us that using an all polyester tray, lidding film and resealable label can be recyclable. However, the packaging can take a while to breakdown, compared to cartonboard. On the other hand, cartonboard and the products Metsä Board are developing have many benefits as illustrated by in this feature. They include being lightweight among other things. However, cartonboard is not good for weatherproofing and can therefore damage the contents. There is no doubt that using these products is a big step forward to making the planet a greener place!
Katie Smith, Category Manager at JDM comments, “Our environmental responsibility is a core value for JDM and we were committed to finding a sustainable solution for our sachets. We were acutely aware that it was a tall order with a hot fill process, not to mention the requirement for a barrier film so that the functionality of the pack would not be impacted”. She continues “We already had a great working relationship with FFP and with their reputation for innovation in sustainable packaging, we were confident they could provide a solution. They didn’t disappoint and the material they supplied runs efficiently at the same speed as our previous film, print quality on the printed material is outstanding and we now have a recyclable solution”.
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SYNERLINK
Synerlink
Sustainability’s vital link Synerlink is a global leader in the development and supply of in-line filling machines for rigid packaging solutions. Jean-Albert Larmaraud, Product Line Director at Synalink informs SPN about the company’s latest developments 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? We are keenly aware of sustainability and it’s a key driver behind our many innovation projects. When working on new projects we take into consideration all possible packaging materials, designs and formats. We aim to build equipment that will enable our customers to reduce their carbon footprint, and in turn contribute to a more sustainable economy.
In relation to sustainability, what would you say have been your most important milestones? One of our greatest achievements in 2020 was the mastering of PET and PP cup pre-cutting on our formfill-seal machines. This is precisely what we achieved with our PS plastic products. Our “Snapcut” innovation has already been sold to several of our customers. Consequently we are now installing this process on new machines and on all our machine upgrades.
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SYNERLINK
In your opinion what have been the most significant developments in terms of recycling and bio-degradable packaging? The increase of PET in recycling streams for water and soda bottles is one of our most significant developments in terms of recent recycling advances. In Germany 97% of PET bottles are recycled and in France 65%. We are convinced that this trend will continue and accelerate. The development of yogurt cups in rPET also represents a big step forward in terms of recyclability.
“ Mastering new plastics and alternative materials offer us the best opportunities � What do you consider to be the most promising market opportunities for your company at this time? Mastering new plastics and alternative materials offer us the best opportunities. In this respect, developing new technology is a vital and continual process. Today our machines can thermoform, cut and pre-cut increasingly thin plastics without sacrificing production speeds and brand image. In addition, our dedicated sorting centres enjoy a better understanding of how to purify each component up to 99.99% purity.(this includes different plastics and colours, etc.). Plastic flakes from trays and cups can be recycled directly by sheet-extrusion or through our depolymerisation and reprocessing systems. Furthermore, our r-PET and r-PS materials are also approved for use in food-contact packaging.
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SYNERLINK
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? Sustainability requirements continue to increase at every step of the way throughout our value chain. Consumers are also increasingly aware of the environmental footprint of packaging. As a result, across the world there are regulatory pressures that cascade down to the FMCG companies and packaging suppliers like us. The constant evolution of materials (PET, PP) and cup components (labels, lids and sleeving etc.) represents a perpetual challenge. However, our advanced R&D programmes enable us to stay on course.
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? COVID-19 has certainly increased awareness among consumers concerning food safety, health, and hygiene. Sustainability has been redefined in combination with hygiene in this new packaging landscape. As mentioned earlier, we believe the increase of recycling streams for PET bottles has been significant, and with increasing demand for yogurt cups in PET, we expect this to have a similar positive effect on the circular economy.
Are you planning the launch of any new products in the foreseeable future that you can tell us about? Our “Snapcut” technology was launched in late 2020 to answer a specific need to accommodate and cut formfill-seal PET in a similar way to that which PS is handled. We will soon tailor our Snapcut technology to accommodate our DairyPack and Dinieper FFS range, which in turn will provide additional support to all our global customers.
How has the Covid 19 pandemic affected your production and manufacturing capabilities?
With the on-going Covid19 situation, we could be facing fewer “new” equipment orders, however our customers still rely on us to upgrade and incrementally improve their current equipment to meet the changing customer demands. The current environment has challenged us to reinvent our business approach with virtual sales meetings, virtual Factory Acceptance Tests (FAT’s) and remote services. Recently, we conducted an Arcil FFS Factory Acceptance Test with a successful 8-hour remote video for one of our customers based 4,000 miles from our facility and it went very well.
www.synerlink.com
“ The current environment has challenged us to reinvent our business approach “ Can you describe your product portfolio and its sustainability credentials? Our FFS (form-fill-seal) machines can produce cups in various plastics adapted to suit different world markets and local recycling streams. Our fill-seal cup machines are also ideal for glass, paper, pottery and bio-source plastics. Furthermore, our fill-seal bottle machines are adapted to suit every type of plastic. Finally, our Combiblow bottle filler uses PET injected pre-forms, which take up less inventory room than preformed bottles and are also easier to transport, thus further reducing our carbon footprint.
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BIOPLASTICS
All set for natural degradability A UK based biotech company is launching the world’s first truly natural biodegradable plastic packaging. The biopolymers used for its biodegradable packaging products are combined with Graphene. This is a natural product derived from carbon, and introduced to create an entirely new generation of fully degradable bio-plastics as Philip Yorke reports. The UK-based biotech company Toraphene is all set to unveil the world’s “first” truly biodegradable, compostable and a commercially viable alternative to plastic packaging. The company has developed a revolutionary new material, also called Toraphene, that uses special biopolymers that compost naturally and biodegrade without human intervention. The biopolymers used for the biodegradable plastic packaging products are combined with Graphene, which is stronger than diamond at an atomic level. Whilst biodegradable plastics currently exist, they rely on commercial composting, which uses energy to heat the compost and can also present other significant logistical and practical challenges. In addition, some bioplastics produce methane gas when they decompose, a compound with a global warming potential 25 times that of CO2. Toraphene founder and CEO Gaute Juliussen said: “Amidst a climate crisis, plastic waste is known to be a huge global problem and many plastic alternatives now exist, so why don’t we see them everywhere? “It’s because they need specific man-made conditions to biodegrade, and many degrade into micro-plastics, which contaminate our oceans and food chains for centuries.” Julussen believes that such bioplastics have “effectively been ‘greenwashed’ and mis-sold to environmentally responsible consumers and companies”.
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Julliussen added, “They also tear easily, shorten the shelf-life of the contents they contain and cannot be produced economically in scale.” Due to the addition of graphene, the company says Toraphene has been shown to be stronger, thinner, and less permeable than alternatives, improving food safety and shelf-life. Juliussen founded Toraphene in 2018 with the initial aim of creating a green alternative to carrier bags and food and drink containers, with such plastics making up 23% of marine waste. Cooperative The Ocean Opportunity Lab’s founder Birgit Liodden said: “Toraphene has the potential to create a critical turning point in tackling the global plastic pollution crisis. “We all know how pressing the climate crisis is, and plastic pollution is a huge problem, particularly in our ocean environments. “I’m very heartened by the prospect of Toraphene, which should be a transformative step in tackling plastic pollution and play a huge role in making the world’s oceans plasticfree.” Ahead of the launch of Toraphene, Juliussen has launched an equity crowdfunding campaign on Crowdcube. In addition to this, Toraphene is renting production equipment from plastic bag manufacturers and plugging directly into existing supply chains. The company is in on-going talks with major consumer brands, retailers and food packaging suppliers. Ultimately, the firm aims to render plastic packaging obsolete worldwide.
BIOPLASTICS
“ deploying environmentally friendly and sustainable solutions to make the world a better and safer place ”
Natural prism Praj has announced its move into the global Renewable Chemicals and Materials industry and is now also offering high quality, sustainable fossil-free packaging products via its portfolio of Bio-Prism products. As a part of its newly launched Bio-Prism™ portfolio, Praj is developing technologies to produce bio-based Renewable Chemicals and Materials (RCM). These are produced from bio-based feedstocks, as sustainable alternatives to products made from fossil resources. On the back of the formidable track record of its BioMobility™ platform for renewable transportation fuel globally, Praj is now making inroads into the RCM industry through its newly launched Bio-Prism™ portfolio. This reaffirms Praj’s vision of developing and deploying environmentally friendly and sustainable solutions to make the world a better and safer place. As a part of its newly launched Bio-Prism™ portfolio, Praj is developing technologies to produce bio-based Renewable Chemicals and Materials (RCM). These are produced from bio-based feedstocks, as sustainable alternatives to products made from fossil resources. On the back of the formidable track record of its BioMobility™ platform for renewable transportation fuel globally, Praj is now making inroads into the RCM industry through its newly launched Bio-Prism™ portfolio. This reaffirms Praj’s vision of developing and deploying environmentally friendly and sustainable solutions to make the world a better and safer place.
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BIOPLASTICS
Revolutionary bio-prism technology
Driving eco-innovation forward
Praj’s Bio-Prism™ portfolio comprises a variety of bio-industrial products, including bio plastics as a priority, along with cellulose-lignin refinery products and specialty products. These products have applications in industry sectors such as automotive, packaging, furnishing, construction, agriculture and food. Over a short to medium term, Praj plans to commit substantial resources for technology and application development with its strategic partners. Speaking on the side-lines of ABLC 2020 Digital.
To put it into context, the chemical industry worldwide is today estimated at US $ 25 trillion annually. Renewable chemicals have a potential to replace a majority of chemicals that are currently sourced using fossil resources. The RCM industry worldwide is estimated to have reached US $ 65 billion and over a decade, is likely to cross around US $200 billion at a CAGR of 11-12%. The Asian market is presently pegged at around US $ 25 billion. The Bio-Prism™ portfolio reinforces Praj’s leadership as an innovative technology solutions provider for sustainability and conservation of the environment. Praj Industries Limited is India’s most accomplished process engineering company in the Bio-economy sector and is driven by innovation and integration capabilities.
Dr. Pramod Chaudhari, added, “Praj pole-vaults into a league of select companies worldwide that are configuring the RCM landscape, with the launch of the Bio-Prism portfolio. Together with Bio-mobility, BioPrism becomes another mainstay of Praj’s contribution to the global Bio economy. “Over the past 3 decades we have developed deep insights and expertise at our R&D facility, Praj Matrix, in processing diverse range of bio-based feedstocks. Our stride in RCM is the result of exclusive work in molecular biology, microbiology, fermentation and chemical synthesis.” Depicting RCM project as “Nature Reimagined – The Promise of Sustainability”, he further added that Praj is open to exploring newer business models with strategic partners. To bring this vision into reality, Praj has technical collaborations with renowned global organizations. Praj has already entered into an overarching MoU with National Chemical Laboratory (NCL) for jointly working on promising project opportunities in RCM space. Praj brings to the table its expertise in technology development, process optimization, integration and scale-up. Praj has also constituted an expert panel of advisors around the globe to help draw-up a strategic blue-print and to guide to the progression of its RCM programme.
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Renewable bio-fuels Over the past three decades, Praj has focused on the environment, energy, and the agri-process industry, with over 750 customer references spanning 75 countries across 5 continents. Bio-mobility™ and Bio-Prism™ are the mainstays of Praj’s contribution to the global Bioeconomy. The Bio-Mobility portfolio offers technology solutions globally to produce renewable transportation fuel, thus ensuring sustainable decarbonisation through circular bio-economy. The company’s Bio-Prism™ portfolio comprises of renewable chemicals and materials solutions, promises sustainability, while reimagining nature. Praj Matrix, the state-of-the-art R&D facility, forms the backbone for the company’s endeavours towards a clean energy-based Bio-economy. Praj’s diverse portfolio comprises Bio-energy plants, Zero liquid discharge plants, Critical process equipment & skids for oil & gas industries, Breweries and High purity water systems.
BIOPLASTICS
Certified biodegradability New jargon enters the world of packaging every day and one could be forgiven for not hearing of the descriptor; Certified Biodegradable Plastics. These are fully Certified Biodegradable Plastics that are making a big contribution to our Circular Economy. For over 30 years BASF has been researching biodegradable and bio-based plastics and has been responsible for the continuous development of these high-quality and high-performance materials that are in such demand today. BASF’s research takes place in close cooperation with its customers, research institutes and local authorities. The focus always lies on the best environmental performance, no matter if the product is manufactured from fossil or renewable resources. For each individual application, environmental safety, cost efficiency and the social consequences have to be examined for a product’s entire life cycle in order to find the most suitable material for the right application with the greatest benefit for society. It should also be checked to what extent the biodegradability offers an added value.
Complimenting conventional plastics Bioplastics do not substitute conventional plastics but complement them as special materials which offer new properties and greater application possibilities. They are, for example, the optimal solution for organic waste bags, compostable fruit and vegetable bags, compostable food packaging or agricultural mulch films.
Correctly employed, biopolymers can contribute to reducing food waste, returning nutrients to the soil by means of greater volumes of compost generated and to avoiding the accumulation of plastics in the soil. Thus bioplastics can make an important contribution to Circular Economy which has the aims to use products in the best way possible across the entire value chain, to keep them in use for as long as possible and to recover them at the end of their service life. Worldwide there is a keen focus on the development of new, more biodegradable bioplastics. Many companies such as BASF have been setting the standards and driving bioplastic innovation forward to create a greener more sustainable future for us all.
“ setting the standards and driving bioplastic innovation forward “ SUSTAINABLE PACKAGING NEWS
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BIOPLASTICS
New ‘Hyper-active’ bioplastic packaging systems The need for more efficient, biodegradable plastics for the food industry has never been greater. There are many new innovative compounds coming onto the market, but only one to date that can also protect against Salmonella. The European Refucote Project is just that, with its advanced new bioplastic packaging systems. The European Refucote Project has developed highly innovative, bioplastic food packaging production processes using renewable materials that are fully recyclable and designed to replace conventional fossil-based raw materials. Three different bio-based active packaging systems have been produced and specifically designed to package fresh chicken meat, cereals and snacks. This is done via the formulation of bacteriophage-based coatings that reduce the proliferation of Salmonella bacteria in chicken breast samples packaged in a modified atmosphere.
Lorena Rodríguez Garrido, a Packaging Researcher at AIMPLAS, the Plastics Technology Centre, and the scientific coordinator of Refucote, told SPN, “Packaging must be recyclable and must also maintain the barrier properties that help protect packaged food. Current packaging has a complex multilayer structure and is made from non-renewable sources. It provides all the protective functions but is difficult and expensive to recycle. Refucote can replace current packaging with more sustainable, better-performing alternatives.”
Of the packaging technologies that extend the shelf life of food, plastic materials are the most commonly used because of their versatility, lightness, ease of handling and strength, which make them uniquely suitable for food packaging. Despite all these advantages, the European Union’s 2018 plastics strategy determined that all packaging must be recyclable by 2030. Meanwhile, consumers’ increased environmental awareness has made it necessary to continue with research to obtain more sustainable packaging.
Performance-plus packaging
Maintaining safe barriers In addition, one of project’s greatest innovations has been the formulation of bacteriophage-based coatings that considerably reduce the proliferation of Salmonella bacteria in chicken breast samples packaged in a modified atmosphere. The project successfully addressed one of the problems faced by packaging with barrier properties: in order to protect food, packaging must be made up of complex multilayer structures that are either difficult or costly to recycle. However, all the packaging systems developed by the Refucote Project can be recycled or converted into compost, which makes them a very promising sustainable alternative to current packaging on the market.
For the last three years, the Refucote Project has focused on three main areas: developing active coatings for food packaging films that use bacteriophage organisms to extend the shelf life of food products and provide a significant reduction in the proliferation of Salmonella in chicken breast samples, the production of polyhydroxyalkanoate (PHA), a biodegradable biopolymer, which is then used to manufacture food trays that extend the shelf life of fresh chicken meat products, and, finally, developing an efficient production process for polyglycolide (PGA), a completely biodegradable material with excellent water barrier properties. This affords it promising applications for food packaging. New technological breakthroughs don’t happen every day and it takes many years to perfect and test such innovative new products. However the Refucote Project dwarfs many other such game-changers by its scope and importance to today’s urgently needed contribution to beating climate change and promoting the circular economy.
For more information go to www.aimplas.es
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PLASTIC PACKAGING
Plastic innovation platform goes globaly
A major new advance in the quest to end plastic waste worldwide has recently been boosted by the opening of three new global hubs by the recently formed non-profit organisation, ‘Alliance to End Plastic Waste’ and early-stage start-up accelerator, ‘Plug and Play’. The group have announced the latest expansion of their ‘End Plastic Waste’ Innovation Platform partnership. The move has been confirmed with the opening of its three new hubs across Shanghai, São Paulo, and Johannesburg. Thus adding significant momentum to their goal of achieving a truly circular economy by 2050. It has also attracted more than 2,000 start-ups worldwide. The Alliance and Plug and Play first launched their platform hubs in Silicon Valley, Paris, and Singapore in October 2019. Since then, the program has attracted over 2,000 start-ups with 32 of them placed on accelerator programs. More than 3 million dollars in capital has been invested and deployed into the start-ups with over 50 commercial pilots between the start-ups and Alliance member companies. Circularise’s block chain technology offers an open source protocol and decentralised platform to bring transparency to global supply chains and empower businesses to move towards a true circular economy. This technology also enables brands, suppliers and manufacturers to choose sustainable and circular materials and present information about products and their supply chains transparently without risking their privacy.
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Recycling ocean plastics Another success story is Oceanworks. The company is collaborating with Avient Corporation, another one of the Alliance’s member companies, through the launch of several new post-consumer recycled and post-industrial recycled portfolios under the reSound brand name. Oceanworks developed a PCR grade with recycled ocean plastics and these grades are formulated for consumer applications which can be used in personal care products, lawn and garden tools, outdoor goods, office supplies, footwear, and houseware durables. Dow has also successfully partnered with ‘Continuous Materials’, ‘Byfusion’, and ‘Empower’ through the End Plastic Waste Innovation Platform. Dow’s primary goal in this partnership was to drive systematic change in plastic pollution and recycling by finding ways to stop the waste and close the loop. Through this combined effort, they plan to divert over 1 million tons of plastic waste to be collected, reused, and recycled. For more details on Dow’s projects with these start-ups, download the case by visiting: www.plugandplaytechcenter.com/dow-hefty-bag/
PLASTIC PACKAGING
Empowering individuals
Baumer’s beating the drum
One final example is Litterati, a start-up from the Silicon Valley hub. Litterati is an app that empowers individuals to make a significant, measurable impact on the environment. The Alliance and its member companies launched World Cleanup Day 2020 with Litterati. The ‘All Together Clean-up Campaign’ was created to clean up the world, one piece of litter at a time. And it achieved that ambition with more than 770,000 litter pickups and more than 75 participating countries.
In the early 2000s, Alex Atala, the world-renowned Brazilian jungle cook bought 62,000 acres of Amazonia land to implement “sustainable farming” and improve the lives of local communities. To gain the tribes’ sympathy, he sent along donations of packaged staples of all kinds to the villagers in dire need. When the time came, he visited his newly bought land only to be shocked by the sight: piles of plastic wraps and bottles thrown everywhere. Upset and disappointed, he called a meeting of the villagers to lecture them about littering and tidy community upkeep. He came to a startling realization: it was rather his fault.
Since then, the relationship with Litterati has expanded. In the future, the Litterati app will be further enhanced with the addition of education elements, machine learning technology to characterize litter, and gamification to engage users. To read more about this engagement, download the case study: https://www. plugandplaytechcenter.com/success-story-litterati/ Nicholas Kolesch, VP of Projects for the Alliance said: “We have been inspired by the start-ups from the first three hubs. To hear from even more locallyrelevant ideas and thinking, we will need to expand our partnership to more locations, and I am delighted that we have landed on Shanghai, São Paulo, and Johannesburg. With the expansion, the start-ups in these three new hubs will be able to access investors and technical expertise through the End Plastic Waste Innovation Platform. Our member companies from the full plastic value chain are ready to support a new phase for the partnership between the Alliance and Plug and Play.”
“ We have had an amazing success rate with the first three hubs ” Kolesch added, “We have had an amazing success rate with the first three hubs. Plug and Play is confident that we will be able to bring together a group of inspiring start-ups with plastic waste solutions for the future of the planet,” said Matthew Claxton, Global Director of Plug and Play’s Sustainability Programme. The End Plastic Waste Innovation Platform was first launched in three cities, Silicon Valley, Paris and Singapore. For further information visit: https://www. plugandplaytechcenter.com/end-plastic-waste/
As he writes in his book “D.O.M.: Rediscovering Brazilian Ingredients”, the tribe chief argued: “For us, the packaging of a fruit is its skin, a fish’s are its scales, an ox’s is its hide, and these things can all be thrown on the ground. You should not have sent us these things wrapped in plastic.” We owe a lot to plastic. Affordable, durable, non-toxic, mouldable in all shapes and dimensions, it is the one product that disrupted all industries in the 20th century and continues to do so even today. Plastic preserved many commodities and countless forests (by replacing wood). It conserved earth’s metals (by replacing iron, copper, and aluminium in many uses), spared numerous lands (by replacing cotton farming through nylon fibre) and ultimately saved entire ecosystems. Hence, this article is not intended as a trial to bash plastic and throw blame. It aims to explain that the plastic era has reached a “tipping point” where producers and consumers need to rethink their need for the use of it.
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PLASTIC PACKAGING
Navigating the new packaging landscape When it comes to solving the challenges posed by plastic packaging, one company stands out from the crowd. TEQ, is a leading manufacturer of thermoformed plastic packaging for some of the world’s biggest companies. The company creates packaging products for a range of different markets, including consumer goods, component handling and healthcare, all developed at its cutting-edge facilities in the UK and Poland. Both have certified cleanroom facilities designed especially for the manufacture of products for the medical sector. It is the company’s clear focus on innovation that allows it to navigate the fast-changing packaging landscape. “Innovative design underpins every TEQ project,” said Anne-Sophie Belamine, the company’s European Sales Director. “We’re focused on finding ways to improve or reduce packaging so that customers get the best designed, and most practical solution.”
Fertile solutions for sterile packaging
For those wanting a plastic alternative, TEQ also offers Fibrepak, a natural and sustainable packaging solution using thermoformed wet pulp. The material is made from locally sourced FSC Chain of Custody certified materials, meaning the pulp used has come from sustainably managed forests. “Regardless of material selection we remain fully committed to delivering innovative packaging solutions, designed and manufactured with sustainability at the forefront of our thinking,” added Belamine.
Baling out a company with big waste problems HSM is a leading manufacturer of baling machines and has provided the perfect solution for a company that was desperate to replace an inefficient and unsafe baler. Tenax is an International Group and a Global Supplier of speciality products such as plastic netting and fencing, pipe protection, construction, agricultural, gardening and DIY products. Tenax was looking for a reliable and efficient baler to dispose of extruded fence netting and grids.
Sterile barrier systems (SBS), the plastic packaging that offers a microbial barrier, usually consist of more than one material. Busy hospital staff don’t have the time to separate lids and trays, so very little of the packaging is recycled.
The new baler was urgently needed to replace their existing inefficient baling machine which was prone to failures and had expensive repairs looming. They turned to the US subsidiary of the German manufacturer HSM GmbH + Co. KG for the answer to their problem.
As a result, the company set to work on creating TEQethylene, a most viable solution for SBS. It worked with its suppliers to develop a better High-Density Polyethylene (HDPE) blend/tray that would be more widely recycled.
“ We’re focused on finding ways to improve or reduce packaging so that customers get the best designed, and most practical solution ”
Using Tyvek, a commonly used breathable HDPE thermoplastic lidding, the firm created a mono-polymer SBS, with no need to dissemble the lid from the tray for recycling. Today customers can choose products that are up to 100% recycled, and all of the materials used are produced from a recycled grade plastic, or are fully reusable or recyclable, with the vast majority of products manufactured containing recycled plastics.
“ Regardless of material selection we remain fully committed to delivering innovative packaging solutions ” 46 SUSTAINABLE PACKAGING NEWS
The perfect solution Every week, Tenax must dispose of around 10-12 bales, each weighing up to 300 kg. Until now, the bales were left loose, messy and cumbersome. This made disposal a big problem for Tenax. The company knew that they needed a better solution to streamline their operation in Maryland USA. HSM was quick to respond to their request for help and was able to provide a test baler so that the company could carry out their own evaluation concerning the quality and engineering of the new HSM machinery.
PLASTIC PACKAGING
“After a torrid time in the media post the airing of the Blue Planet II series on the BBC, plastic packaging has interestingly had something of a renaissance during the Covid-19 pandemic. Consumers have prioritised health, safety and hygiene over other needs, recognising the substrate’s fundamental protection and preservation qualities in the packaging of grocery and sensitive goods. That being said, a number of legislative changes are on the horizon that will impact the production of plastic packaging in the coming months.
With the latest HSM V-Press 860 plus B baler, Tenax has optimised its disposal of waste materials, and can now sell the bales to scrap vendors. The advanced HMSM baler has an ergonomic design with a lower feeding height. The bales are made denser, thus making it easier to double stack them. As a result the company benefits from more working space in its warehouse locations. In addition, the base of the bales will not fall apart, making for a cleaner working space. Tenax is now spending far less on maintenance, enabling this global supplier to continue to grow and be assured it is disposing of all its waste materials efficiently and safely. SPN has seen the reliability offered by HSM equipment, which meets the expectations of all who have benefited from its unparalelled German engineering credentials. There are probably many more companies that could be ‘baled out’ by MSM!
“ Tenax is now spending far less on maintenance, enabling this global supplier to continue to grow ” Taxing considerations The packaging industry’s marketing and strategy company, ‘eco-Veritas’ offers us some useful insights into what’s on the horizon in relation to forthcoming legislation. Forewarned is forearmed, so here at SPN we believe that it is never too early to look at the proposed plastic packaging legislation which comes in to force in April 2022. David Harding-Brown is CEO of ecoVeritas and he made the following observations.
“ we will soon begin to see the impact of a new EU Plastic Packaging Levy designed to discourage the use of non-recyclable plastics ” “First of all, a new UK plastic packaging tax is slated for implementation in April 2022, mandating that plastic packaging manufacturers and importers that do not meet a 30% recycled plastic content requirement will be subject to a levy of £200 per tonne. For companies that are worried about what these cost implications may mean, we advise that you start preparing now by identifying where your liabilities reside and start to optimise wherever possible. “Secondly, we will soon begin to see the impact of a new EU Plastic Packaging Levy designed to discourage the use of non-recyclable plastics. EU member states will pay a ‘call rate’ of €800 per tonne, which will go into the EU’s Covid-19 relief fund. Following Brexit, the UK does not have the same obligation to pay into the scheme as EU member states, but businesses in the UK that export plastic packaging will likely see a significant cost increase as EU member states seek to offset their costs on their suppliers. At ecoVeritas, we know there’s a storm coming, but as an industry we’ll ride it out together”. With the current shadow of the Covid 19 pandemic still hanging over us, and the resulting impact of additional costs and restrictions, then making contingency plans becomes a priority. In these circumstance every little helps. With that in mind, SPN will continue to bring you the latest news and coverage of the market forces affecting our industry.
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SEALED AIR
Sealed Air
Sealed Air is a global manufacturer of protective packaging and is responsible for some of the world’s best known brands. Ed Roberts – Global Sustainability Leader of Sealed Air, informs SPN about the company’s latest product developments 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? In 2018, Sealed Air announced a bold sustainability and plastics pledge, with a commitment to design future packaging solutions to be 100% recyclable or reusable by 2025. The pledge also includes a target of 50% average recycled content across all packaging solutions, of which 60% is post-consumer recycled content. Based on as assessment at the end of 2019, 27%, of Sealed Air’s portfolio was designed for recyclability or reuse. We expect to deliver approximately 50% recyclable or reusable solutions by the end of 2023. This pledge is a big step in the direction to help improve key areas of the circular economy, including climate change, food waste, safety and security, resource availability and depletion as well as the need for more infrastructure.
In relation to sustainability, what would you say have been your most important milestones? In 2020, Sealed Air announced a collaboration agreement with Plastic Energy, a leading Londonbased, company that specialises in advanced recycling technology. This collaboration will accelerate the development of new technology with an infrastructure that can allow more plastic waste to be recycled and put back into packaging, rather than ending up in a landfill or in the environment.
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In 2020, Sealed Air also announced a multi-stakeholder pilot project with Tesco that created a closed-loop process for recycling flexible plastic dropped off by Tesco shoppers that was eventually recycled into packaging used for cheese sold at the stores. Sealed Air’s role in this closed loop was to redesign existing packaging to include 30% recycled plastic content that met the requirements needed for safe and effective use in food packaging.
In your opinion what have been the most significant developments in terms of recycling and bio-degradable packaging? This aligns to the answer above with our collaborations with Plastic Energy and Tesco; advanced recycling technologies, such as pyrolysis, gasification and glycolysis which offer a significant opportunity to recycle complex multilayer plastic films to a virgin-level quality that meets food safety standards.
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? Assessing the full life cycle of a packaging solution and looking at ways to optimise the materials used in creating it is a key driver for our business. This means taking a look at how it can be recycled, while also incorporating more recycled content into the product in the first place. This ties back to our 2025 Sustainability and Plastics pledge, specifically the goal of using an average of 50% recycled content in our products.
SEALED AIR
Can you describe your product portfolio and its sustainability credentials? Organisations – businesses, NGOs, charities etc. – assess sustainability of a product or service across three areas: environmental, social and economic. Environmentally, will the solution reduce emissions and waste, and support biodiversity? From a social standpoint, will the solution improve health and safety, promote diversity and community outreach? Economically, will the solution improve capital efficiency, margin improvement and enhance growth? We also need to consider that the level of environmental importance varies in its application to sustainable materials, such as water, energy, waste, effluent, land use, animal welfare, greenhouse gas emissions, transportation, design and operation and supply chain compliance. Having evaluated the sustainability goals of over 300 organisations, no two are the same, even those in the same market in the same country. What is meant by sustainability credentials? Every business, every salesperson knows the features of the products and services they sell but do they (a) truly know the sustainability features and (b) do they know the sustainability benefits of the features?
The sustainability benefits our customers are looking for are unique to them, and we work with them closely to understand these needs and deliver the right packaging solutions to meet their specific requirements.
How has the Covid 19 pandemic affected your production and manufacturing capabilities? Throughout the pandemic, Sealed Air has been providing essential packaging solutions needed to help in the fight against COVID-19. These include things like retention packaging, custom-fabricated shipping boxes and automated packaging and bagging systems that can be used to package medical equipment, face coverings and test and vaccine kits. We are also introducing a new innovation called SEALED AIR© brand TemPreserve KF, a customisable polyurethane packaging that helps to maintain required temperatures (ultra-cold, cold or hot) for a specific length of time needed during transit and can be used for vaccine packaging. SEALED AIR® brand New Air I.B.®
Take for example, SEALED AIR® brand New Air I.B.® which is an inflatable plastic bubble system for cushioning within packaging. It uses our patented Barrier Bubble,TM which retains air longer than other bubble materials and so provides high cushion levels. Few would describe ‘high cushion’ as a sustainability feature but ’high cushion’ leads to reduced product damage which in turn leads to a reduction in resource use, reduced transportation, improved driver safety, reduced fuel use, reduced greenhouse gas and reduced waste. Similarly, for food packaging, CRYOVAC® brand Darfresh® Rollstock is a vacuum skin packaging system. ‘Vacuum skin’ is a product feature but is not a sustainability feature. Instead, we focus on the sustainability benefits which this feature brings. For example, the vacuum packs are smaller than thermoform or MAP packs so more can be refrigerated and transported in the same space, which means fewer lorries on the road, less energy used and reduced CO2, and lower costs.
CRYOVAC® brand Darfresh®
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CORRUGATED PACKAGING
Corrugated board the new ripple effect
No matter where you look today creativity and innovation abound in the world of corrugated packaging. Recognised as the packaging sector with the greatest potential for growth, it continues to surprise. In a strange twist of fate, the Corvid 19 pandemic has led to a ripple effect in the creation of a whole new spectrum of innovative solutions.
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CORRUGATED PACKAGING
The surge in new corrugated packaging innovation has not only been driven by the big players such as Smurfit Kappa and D.S Smith but also by some of Europe’s fastest rising stars, such as EPK and EuroBox Polska, a subsidiary of Dunapack Europe. Innovation has also been driven by dramatic changes in consumer trends and demands. However, the move towards corrugated packaging is particularly evident in the pharma packaging sector where strict specifications and tight tolerances come as standard. In the on-going Covid-19 pandemic, readiness to respond quickly to market forces and provide industry expertise has become paramount in making vital healthcare products available. The DS Smith Pharma Business Unit and its worldwide network of designers is helping to deliver faster, innovative and more sustainable packaging solutions to the healthcare industry than ever before.
Speed - the game changer Faster project development has become a game changer during the Covid pandemic. DS Smith’s packaging designers across world markets have had to provide fast and crucial support, especially to its clients. The company has initiated the development of a number of urgent packaging concepts for life-saving products such as vaccines, diagnostics and hospital medical devices.
Fast project delivery In highly pressurised times like these, in-depth knowledge of the healthcare industry is critical for fast project delivery. DS Smith has always responded to this need by creating a pharmaceutical and medical business unit to leverage expertise and manage projects globally. The company’s pharma experts bring innovative solutions to customers with a clear focus on sustainability, by optimising resources, and increasing efficiency.
Global developments Today the corrugated packaging market is growing fast, helped by the explosion of e-commerce and new developments in digital printing technologies. In fact it is growing faster than expected, confounding some predictions that forecast a slowdown in corrugated consumption. A downturn in demand in China and the banning of contaminated recycled paper stocks has not fully materialised.
Smithers the research house, has published a searching new report called; The Future of Corrugated Packaging to 2023. It offers exclusive analysis on how this market is increasing, growing around 3.7% annually to reach $300 billion in 2023. The report also reveals that the electrical goods end-use sector will see the highest levels of growth. SPN believes that the latest report from Smithers makes for essential reading.
If the Kappa fits… There has been an unexpected surge in consumer demand for Bag-in-Box wines in 2020, according to new data, caused in part by changing consumer behaviour. Much of it due to the Covid-19 pandemic. Research by packaging leader Smurfit Kappa in collaboration with ‘Wine Intelligence’ found that Bag-in-Box wines attracted 3.7 million new consumers in France and the UK during the past six months and fitted in perfectly with the consumer trend in Europe towards Bag-in-Box wines. The survey analysed the behaviour of monthly wine drinkers in France and the UK, who have increasingly moved to drinking and entertaining at home due to the restrictions of the pandemic. France is the biggest market for Bag-in-Box wine and the UK is currently one of the fastest growing. Consumer panels said that freedom of consumption, ease of transport and value for money as the main motivations when purchasing Bag-in-Box wines. Other benefits include its ability to preserve wine for up to 6-8 weeks after opening compared to 2-3 days in a glass bottle, this is in addition to its lower carbon footprint. Commenting on the survey findings, Thierry Minaud, CEO of Smurfit Kappa Bag-in-Box, said: “The future is bright for our Bag-inBox solutions with the research finding that 4.4 million consumers are potential buyers of the product in the next six months.” Minaud added, “Bag-in-Box offers brands a more sustainable, cost effective and consumer-friendly packaging solutions that meet current consumer expectations, which explains its unrivalled success and strong market growth.” The survey found that four in ten potential Bag-in-Box wine buyers were under the age of 35 and would like to see smaller formats of the product. Of those who frequently purchase Bag-in-Box wines, the research found the three litres option is the most favoured Bagin-Box wine product.
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CORRUGATED PACKAGING
New zero emissions deal In another move towards achieving zero emissions and setting new industry standards, Smurfit Kappa has just announced new targets to further reduce its fossilbased CO2 emissions, including its ambition to reach at least net zero emissions by 2050. It has also increased its existing intermediate 2030 CO2 reduction target by 15 percentage points to 55%, in comparison to its 2005 baseline. The company will have these targets validated by the Science Based Target initiative as being in line with the objectives of the Paris Agreement. Smurfit Kappa has been a market leader in sustainability since 2005. Before today’s announcement, the company had already achieved a reduction in CO2 emission intensity of 32.9% on its 2030 target of a 40% reduction. This impressive achievement has resulted from the successful implementation of key projects that form part of the company’s medium-term strategic plan. Speaking on behalf of Smurfit Kappa, Tony Smurfit, Group CEO said: “We are proud to support the EU Green Deal objectives to reach net zero emissions by 2050. We have made good progress on our existing targets and these new targets underline the organisation’s continued commitment to sustainability and to do better for the planet. Sustainability has been at the core of our business for decades, we want to lead from the front and raise the bar for the paper and packaging industry by setting such ambitious targets. This is a source of pride for all our customers and employees.” Smurfit added, “Sustainability has always been part of our DNA but concerns about how we treat our planet, how we create a more inclusive world and support greater equality across our communities has never been so important. More needs to be done to address these global challenges. That is why we are setting new, more ambitious short-term targets and longer-term goals. Better Planet 2050 quantifies our commitment to protect what we care about – our planet, our people and our business - through a set of ambitious goals that will drive actions and behaviour that delivers better outcomes.”
“ how we create a more inclusive world and support greater equality across our communities has never been so important ” 52 SUSTAINABLE PACKAGING NEWS
CORRUGATED PACKAGING
India - the Asian window to watch When it comes to corrugated packaging India is the window of opportunity to watch. It possibly offers the greatest scope for growth in the world at this time. India’s fast-growing Corrugated Paper Packaging Market is projected to grow at a 7.6% CAGR for the next five years due to its strong demographic and economic prospects. India is also among the fastest growing economies in the world, with a per capita income projected to increase by 50%, to USD 3,000 by 2023. India is also home to the largest growing pool of young, income-earning consumers (median age of 28 years). Moreover, current urban population (33%) will grow to reach 40% by 2025. GI Packaging Pvt. Ltd. is one of India’s largest manufacturers and exporters of corrugated boxes. It started its journey 33 years ago as a manufacturer of lightweight corrugated boxes. Later its design and package engineering experience were called upon for more heavy-duty applications. The company has now operates fully automated state of the art machines to manufacture high quality corrugated products and deliver excellent value to its customers, whilst operating in a manner that maintains its commitment to the environment.
The company currently produces more than 33,000 tons of corrugated boxes per annum and plans to significantly expand its capacity. TGI takes it as a challenge to continually raise its standards in order to ensure its on-going high degree of customer satisfaction.
Proven performance in Poland The European market is no exception when it comes to seeing strong growth in the corrugated packaging market. One of its leading lights is Eurobox Polska. This well-established company is a manufacturer of high quality corrugated cardboard and packaging in Poland. The company was established in 1998 and is a part of Dunapack’s European Packaging Division, the largest professional manufacturer of paper, corrugated cardboard and packaging in Central Europe. Eurobox Polska is a part of Dunapack Packaging, the largest manufacturer of paper, corrugated cardboard and packaging in Central Europe. Its present share of the market in corrugated cardboard and packaging is 5%. In 2009, sales reached more than 130,000sqm of square meters of corrugated products. At present packaging accounts for almost 80% of the company’s sales.
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CORRUGATED PACKAGING
Thermal shipments heating up It is becoming increasingly clear that consumer shopping habits have drastically changed over the past months. The response to the Covid-19 pandemic has translated into an acceleration of e-commerce adoption. Indeed, recent research from DS Smith reveals that European consumers plan to continue or increase buying groceries online (62%) and home meal kits (49%). One area of particular focus for consumers is confidence in the quality and sustainability credentials of the packaging that their order arrives in. Or more specifically: understanding what its impact is on the environment. To answer the sustainability challenges raised by the growth in e-commerce, DS Smith and TemperPack are partnering to introduce ClimaCell®, a sustainable thermal insulation barrier for temperature sensitive goods such as meal kits, perishable groceries and medical products. The secret of this latest development lies in its ClimaCell® gel packed which maintain the required temperature between the inside and the outside. A special corrugated box protects the contents during shipment. The new ClimaCell® thermal liners, make it is easier to tackle consumers concerns about the environment. The product, which is made from paper and bio-based materials, can be easily recycled in paper recycling bins by the consumer after use. It will replace the difficult to recycle EPS (expanded polystyrene) foam, over 350,000 tonnes of which is used in packaging annually, with just a third of this plastic packaging waste being recycled in Europe. Furthermore, switching from EPS foam to ClimaCell® reduces harmful carbon emissions by 65%. At SPN we continue to monitor the key developments in the market place to provide you with the tools to improve your overall efficiency and sustainability… as well as your profits.
Reaching higher global standards Rigid Containers is part of the VPK Packaging Group and a leading supplier of sustainable corrugated packaging, has attained its first BRC Global Standards Higher Hygiene and The American Institute of Baking (AIB) certification.
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The accreditations were earned by the company’s Wellington site, allowing Rigid to build on its packaging solutions to the food and drink sector and now supply direct contact packaging to manufacturers. Over half a million pounds was invested by the business in readying the Wellington site for both the BRC and AIB audits, with improvements made to the building, equipment upgrades and enhanced training for staff. The accreditations also enable Rigid to offer an ideal solution to companies looking at transferring from plastics to more sustainable packaging solutions. The BRC Global Standard for Food Safety is developed by food industry experts from retailers, manufacturers and food service organisations to ensure it is rigorous and detailed. It provides a framework to manage product safety, integrity, legality and quality, and the operational controls for these criteria in the food manufacturing, processing and packing industry. With the market place in a period of transition, the best way forward is to understand what is happening right now and optimise any positive market trends. At SPN we are committed to providing the broadest coverage of sustainable packaging news in Europe and around the world. We will continue to monitor the key developments in the market place to provide you with the tools that will enable you to improve your overall efficiency and sustainability…as well as your profits.
LUXURY PACKAGING
At its finest! In this ‘luxury article’, Emily Dimas delves into the advantages that luxury packaging can have on the environment and the overall impact it has on reducing the carbon footprint. The niche fragrance label Différentes Latitudes launches a new eco-conscious range, with a cork cap from international beauty packaging manufacturer and provider Quadpack.
“ although my mission was to develop beautiful premium fragrances, they should have the least possible impact on nature ” French perfumer David Frossard had an epiphany while travelling in India a few years ago. Tired of the city, he took a rickshaw to go to the beach and connect with nature, but was disappointed when he finally reached the seaside, completely polluted with plastic and other various items of garbage. “It became obvious to me that, although my mission was to develop beautiful premium fragrances, they should have the least possible impact on nature,” he said. From the ingredients to the outer pack, everything was carefully considered in order to avoid waste. “The impact of the cap says a lot about the product: it’s disruptive, trendy, natural and modern at the same time,” he added. Fully manufactured in Europe, Obvious was developed for what Frossard calls ‘the European style’. “The luxury fragrance market nowadays is directed mostly at premium clients from America, Asia and the Middle East, both in terms of price positioning and marketing. “I wanted a product that would resonate with Europe again,” he explains. Initially sold through the crowdfunding platform Ulule, the new range has adapted to the ‘new normality’: clients can receive the seven fragrance samples at home, pick their favourite, and then have the full bottle delivered to their door.
Striking gold Proving that packaging can be both luxurious and sustainable, Stoelzle Glass Group have been awarded GOLD status by the renowned ECOVADIS platform! According to the strict Ecovadis Methodology, which is based on international sustainability standards such as Global Reporting Initiative, United Nations Global Compact, and ISO 26000, Stoelzle Glass Group ranks within the top 4% of all Glass Manufacturers assessed by Ecovadis.
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LUXURY PACKAGING
“We are proud about our promotion to the Ecovadis Gold status. This remarkable rating results clearly from our success in reaching a couple of important sustainability milestones, such as the certification according to ISO5001 and ISO14001, the publication of our 2nd GRI based Sustainability Report, our Groupwide Code of Conduct, as well as the successful implementation of a Sustainable Supply Chain Management,” underlines Georg Feith, CEO of the Glass Group. SGK Anthem, Vrijdag Premium Printing, Generous Minds, Neurensics, Kurz and Merck have joined forces under the name ‘Packadore Collective’ to design and implement both desirable and sustainable packaging solutions. Their Natures Candles packaging design demonstrates how premium home fragrance and luxury lifestyle brands can create connections with their consumers beyond scent.
Exclusive sustainability It’s well known that smell is the most powerful of all our senses with strong ties to both emotion and memory. But how can premium home fragrance and luxury lifestyle brands create connections with their consumers beyond scent? With the rise of the ecoconscious consumer, brands need to be mindful of the sustainable credentials of their products and their packaging. SPN has been given exclusive content as to how Packadore Collective ensures the deluxe packaging can be sustainable too!
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‘Natures Candles’ is a concept design innovation that uses NatureWax® made from hydrogenated soybean oil and non-hazardous vegetable derived additives. The candles themselves are made from and burn using natural and organic materials. The glass packaging is easily recyclable due to the use of a mono material and due to the lack of additional plastic or glue coated paper labels. For more information go to : www.spnews.com/desirable-and-sustainable-candlepackaging-design-using-natural-mineral-powders/
LUXURY PACKAGING
Growth in on-the-go eating, use of pharmaceuticals for an ageing population, the need to create ‘stand-out’ on crowded shelves and, of course, pressure to reduce use of plastic are just some of the factors driving the increasing demand for paperboard. But how can packaging producers help their clients to meet this demand while also keeping their sustainability targets on track? SPN investigates! Antalis began developing its range of sustainable products and supporting services more than two decades ago and now has one of the most innovative offerings on the market. Key to the credibility and success of this portfolio is the company’s careful selection of suppliers who share Antalis’ focus on providing high quality products, sustainably. “Concerns around the use of plastic packaging, particularly single-use packaging, has led to a significant rise in demand for fibre-based graphic and cartonboards that are renewable, biodegradable, recycled or recyclable”, says Steve Chappell, Graphical Board Development Manager “At Antalis we also ensure we work with suppliers who have strong environmental ethics, like Iggesund and Metsä Board.” Antalis stocks Iggesund’s world-leading paperboard brands Invercote and Incada, which are renowned for their durability and design versatility. Iggesund’s mill in Sweden, where Invercote is made, and its UK mill in Workington, Cumbria, where Incada is manufactured, have both been awarded Platinum level by the international assessment company EcoVadis.
Produced from virgin fibre of known and traceable origin, Incada is made at a mill that produces 100% of energy from renewable biomass, and is the only folding box board (FBB) manufactured in the UK, giving it a very low carbon footprint for UK customers. Invercote, solid bleached board (SBB), made from pure virgin fibre sourced from sustainably managed Swedish forests, is known for its strength and toughness and taint and odour neutrality making it particularly suited to packaging where demands on print quality and structural design are very high. Steve comments, “We have one of the most comprehensive ranges of paperboards in the UK. We’re continually reviewing our range of products and suppliers to ensure they are as sustainable as possible, and I am excited to say that we will be expanding our portfolio with new and innovative products, with the highest environmental profile, in the near future.” For more information go to : www.spnews.com/meetingrising-demand-for-paperboard-sustainably/ To summarise, to make a luxury item look good there is no need to produce packaging which cannot be recycled! Différentes Latitudes have shown us that cork packaging is extremely sustainable and has no harm on wildlife, a huge step forward to protecting our environment! Stoelzle Glass Group have taught us that glass packaging may be the way forward. They have been awarded GOLD status by the renowned ECOVADIS platform. This, along with everything else in this feature, contributes to our combined efforts to making the planet a better place for our children!
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Bottles v Cartons
Bottles V Cartons In this special feature of “Bottles v Cartons” Emily Dimas investigates the benefits of both bottles and cartons with regard to their environmental impact. SMI offer a wide range of rotary stretch-blow moulders available in stand-alone or ECOBLOC® version, integrated with filling and capping modules for the production of PET and r-PET containers up to 36,800 bottles/hour. Recent studies show that there are many benefits for using plastic bottles. For example, plastic bottles are unbreakable, lightweight and recyclable when compared to other packaging materials such as glass or aluminium. PET has a good environmental profile which due to its lightness, it translates into less material to produce, less material to dispose of, less energy to manufacture it and less fuel to transport the packed products. SMI are manufacturing stretch-blow moulders, which are the ideal system for producing PET and r-PET (recycled PET) bottles. Another benefit of bottles is that the sleeves can now be recycled too! Siegwerk have developed a proprietary washable ink technology that enables deinking of UV/ LED-printed PET shrink sleeves allowing for a recycling of the sleeve along with PET bottles.
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Fabian Kohn, Global Product Manager Narrow Web at Siegwerk states, “With our AQUANTUM Alkali Strippable Primer and SICURA UV/LED inks, we developed a solution especially allowing safe and efficient deinking of crystallisable PET shrink films printed with UV/LED inks following the APR’s deinking and recycling criteria. The deinking of UV/LED-printed sleeves represents a special challenge for recycling. As standard UV inks form a solid, chemically, and mechanically resistant layer they are not easily and, in most cases, not completely removable from the substrate and therefore minimize the quality of the recycled material.”
Bottles v Cartons
Multi-packing sustainability Bottles can also be multi-packed sustainably too! VPK Group, one of the founding members of the panEuropean alliance Blue Box Partners, has launched ECOGRIP, a corrugated alternative to shrink wrap for the multi-packing of a wide range of bottles that builds on the growing consumer demand for sustainable packaging. The EU’s single-use plastic (SUP) Directive, which came into force on 3rd July 2019, aims to reduce the impact of certain plastic products on the environment. This has caused large brands and manufacturers to re-evaluate their packaging strategies and seek out alternatives. CCL Label are now supplying NÖM with their innovative EcoFloat™ sleeves. The renowned Austrian dairy brand NÖM (Niederösterreichische Molkerei) is now selling their 1 litre rPET milk bottle from Alpla in a PET bottle made of 100 percent recycled PET (rePET) with the goal of lowering the CO2 footprint by using recycled materials and also supporting a more circular economy. PET is the most recycled plastic packaging material in Europe!
Inex, Belgium have made the switch from carton to white PET! To help Inex better understand the benefits of the move, Sidel supported Inex in verifying experiences and also by visiting a similar installation. “Sidel was an excellent cooperation partner. All viewpoints they offered made it clear to us how beneficial the new line would be,” comments Steven Dierickx, CEO at Inex. Some of the most important considerations focused on the fact that PET is not only a perfect match for safe and shelf-stable low acid products, but that it is also a 100% closed-loop recyclable material. In addition, production with Sidel’s Aseptic Combi Predis™, a blow-fill-seal solution with dry preform and cap sterilisation, is much more environmentally friendly. No water is consumed and very few chemicals are used to sterilise the bottle during production.
“Although the label or sleeve only may seem like a small part of the overall packaging, choosing the right label is very important when designing packaging with the endof-life in mind. ´Design for Recycling’ guidelines show that a floatable polyolefin material with a low density is ideal for high-quality PET recycling”, says Wolfgang Ploesch, Business Development Director at CCL Label. “The polyolefin flakes are separated from the PET flakes in the so-called sink/float process and are sorted into the right material streams. This supports bottle-tobottle recycling and in the end…a closed loop.”
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Bottles v Cartons
Standing out from the crowd The new PET packaging stands out from the crowd when compared to traditional carton packaging. The white PET bottle ensures stable light barrier properties for long-life and product integrity without any aluminium foil. “The new PET bottle contains a minimum of 25% recycled PET, is 20% lighter than other plastic (PE) bottles and therefore has a 20% lower CO2 footprint, comments Steven Diereckx. In the carton industry, companies are coming together in their efforts to be even more sustainable! Stora Enso and Tetra Pak are joining forces to explore the possibility of building a new recycling line to significantly increase the recycling of used beverage cartons in Central and Eastern Europe. The two partners are initiating a feasibility study to assess the viability of building a large-scale recycling line for Used Beverage Cartons (UBC) at Stora Enso’s Ostrołęka Mill in Poland. If realised, the annual capacity of the new recycling line would be 50 000 tonnes of UBC. This would be a significant increase in recycling capacity for beverage cartons across Europe, boosting the European beverage carton recycling rate from the current 51%.
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“A new line would be the next step in the circularity of packaging materials, in helping make our customers’ brands circular. Beverage cartons are widely recycled in Europe today and we want to use our knowledge of fibres and board to promote and accelerate the recycling and collection of beverage carton materials. Our process at Ostrołęka Mill already uses recycled (OCC) materials. We are interested in developing the already well functioning recycling system and using high-quality UBC fibres,” says Markku Luoto, VP LPB Aseptic and CUK, Stora Enso.
“ we will be able to lead the sustainability transformation ” “Working with partners along the value chain is our number one priority when it comes to driving collection and recycling of used beverage cartons. We are confident that this partnership will allow us to improve Europe’s recycling infrastructure and further increase the recycling rate of UBC in the region. It is through synergies like this one that we will be able to lead the sustainability transformation and achieve a low-carbon circular economy,” says Guillaume Latourrette, Managing Director, Tetra Pak East Europe.
Bottles v Cartons
Legislation driving cardboard packaging In Europe, the trend towards cardboard has already become very significant due to rigorous legal requirements. Packaging machine manufacturer Schubert is also experiencing this. “Cardboard is now in even greater demand by manufacturers,” confirms Valentin Köhler. With this in mind, it is a good time to rethink your packaging – and all the more if you’re planning automation. Especially in the concept development phase of a new packaging machine, there is a great deal of scope for assessing your product packaging / sustainability and to use more cardboard in packaging development. Valentin Köhler is convinced it is practically always possible to develop machinecompatible functional packaging made from cardboard. Pro Carton – the European Association of Carton and Cartonboard Manufacturers have developed an amazing way of teaching all generations about the importance of sustainable packaging and the biodegradable nature of cartonboard. During National tree week late last year, families were encouraged to plant a tree sapling (or a cutting or seed) inside a biodegradable carton and then into the ground. Tony Hitchin, General Manager of Pro Carton said: “National Tree Week is something that Pro Carton can really get behind, as it brings people together with the sole purpose of planting and protecting trees to help save the environment. It is unfortunate that some areas may not be able to take part in community plantings due lockdowns, so we hope TICCIT (trees into cartons, cartons into trees) at Home will help to continue this important work. It makes for a great activity for families to complete together as they can make a direct positive difference and learn all about the important role that trees, packaging and recycling play in the protection of our planet.” Bottles undoubtedly have many benefits, including being unbreakable, lightweight and recyclable. They have played a huge part in the packaging industry for over 70 years now and will do for many more years to come. PET is not biodegradable though and even PLA alternatives need ideal conditions to break down. Cartons can also be recycled and can be biodegradable too! The average weight of a 1L carton with a lid is 30g compared to the average weight of a 1L plastic water bottle which is around 18 grams.
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Recyclability
Back to the future The race to ensure a better future for us all has begun. During a year of constant change and uncertainty, the packaging industry has fought hard to maintain its high standards and proven to be extremely resilient in the face of a series of catastrophic global Covid 19 lockdowns. Demonstrating clear leadership and resourcefulness, the world’s packaging companies have not only weathered the Covid storm, but in many cases, found gold at the end of the rainbow. Looking back at the year 2020 and how the packaging industry has responded to the Covid 19 pandemic, people within the industry can be justly proud of the part they have played and today continue to play in maintaining supply and distribution. Throughout the year companies have remained surprisingly positive and produced their most creative solutions, not only by improving the recyclability of their products, but also by becoming even more efficient with regard to their own supply chain management and production operations. This trend appears to be continuing in 2021. One of many examples that stand out today is that of Coca Cola, whose response to the need for much greater recyclability has led to a ‘game changer’ in their drive to achieve their goal titled, “World Without Waste”. The result is the development of a coke bottle made 100% from paper. The company’s ambitious plan is to be able to collect and recycle a bottle or a can for every single item that they sell. Furthermore, Coca-Cola plans to use only packaging materials that are 100% recyclable.
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Recyclability
Coca-Cola told SPN, “We aim to collect and recycle a bottle or a can for every one that we sell by 2030, whilst also substantially reducing our use of virgin packaging materials and only using packaging materials that are 100% recyclable. “It will take continuing investment in innovation, exploration of different technologies and, crucially, partnership and collaboration to get there. This is fundamental to our approach, across both the collection and recycling of our packaging but also its design. “As part of this, we have been working to explore the concept of a paper bottle with our partner, Paboco, and the three other companies in the Paboco Pioneer Community. And we are now at the stage of a first generation prototype ready that we believe can play a part in helping to achieve our goal of a “World Without Waste”. “Our vision is to create a paper bottle than can be recycled like any other type of paper, and this prototype is the first step on the way to achieving this. A paper bottle opens up a whole new world of packaging possibilities, and we are convinced that paper packaging has a role to play in the future,” said Stijn Franssen, EMEA R&D Packaging Innovation Manager at Coca-Cola who is working on the project. However a lot of work has yet to be done to achieve this vision of a recyclable paper bottle. The first-generation paper bottle will still contain a small degree of plastic. “This first-generation paper bottle prototype still consists of a paper shell with a plastic closure and a plastic liner inside. The plastic we use is made from 100% recycled plastic that can be recycled again after use. But our vision is to create a paper bottle that can be recycled like any paper can be. The next step is to find a solution to create a bottle without the plastic liner,” added Stijn.
Going green for kids It isn’t only the FMCG industry giants that are investing heavily in a concerted drive to improve the recyclability of their product packaging. The Berlin start-up Erdbar is on a mission to bring healthier, organic baby foods and recyclable packaging to children via its “Fresh Friend” range of products. These innovative products are marketed under the entrepreneur’s “Little Leaf brand, which utilises Wipac’s revolutionary ‘Squeeze Pouch’ technology and water-based digital printing. The Little Leaf brand offers fresh organic baby food straight from the chiller cabinet, thanks to an innovative bio-quality production process. The new range includes eight flavours, made up of three types of fruit, four vegetable, plus one of meat, the Munich-based start-up company Little Leaf recently launched its products onto the DACH markets. Little Leaf owner Sandra Peralta first came up with her business idea about four years ago, working independently to develop the formulation and arranging production in Bavaria. The entrepreneur who already operates a catering service company in Munich breathed new life into the supplementary food segment for biological products, increasing nutritional awareness and health consciousness amongst young parents.
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Recyclability
A greener squeeze The squeeze-pouch snack for kids comes in green packaging with Freche Freunde as the perfect option. The Berlin start-up Erdbär has a mission: “to bring pep into the world of healthy baby & kids food with their “Freche Freunde / Fresh Friend” brand”. “The goal is to help children to develop an early friendship with fruits and vegetables and this is easiest when it’s made fun!” says Jan Augenstein from Erdbär. But not only a funny design carrying the message. All products are made to organic quality standards without any chemical additives. It was clear to us that the packaging had to protect our product and fit in with our cheeky concept. We deliberately wanted to dispense with aluminium in our Squeezie pouches and use a sustainable packaging solution”, says Jan Augenstein.
Recyclability shaping the future Following trials, Erdbär decided on adopting Wipak’s new concept for squeeze pouches, which consist of a combination of FSC®-certified paper and a green PE sealing layer. This composition makes up more than 60% renewable resources and also saves 25% on the plastic content. The bold designs are printed with water-based inks using Wipaks innovative ProDirect® digital printing technology. With the overall concept, Erdbär underlines its responsibility towards future generations and its belief that sustainability and recyclability will shape the environment of the future.
“ Erdbär underlines its responsibility towards future generations ” Creating “AAA” recyclable purity Throughout 2020 packaging companies reacted with the formation of special crisis response teams and focused on protecting their employees’ health as well as making practical operational and management changes. Leadership teams looked for new niche pockets of growth potential using different packaging product designs and novel substrates. Today with Covid 19 vaccinations gaining momentum across the globe, packaging company leadership teams now need to look for any shifts in consumer sentiment, such as e-commerce and hygiene requirements as well as possible resurfacing concerns regarding recyclability.
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Recyclability
Looking back, Allfo vacuum packaging is a perfect example of how a company has successfully managed the Covid 19 pandemic and prepared in advance for the opening-up of world markets. The latest product of Allfo’s creativity is its VAC 95+ sustainable, recyclable and sealable vacuum-formed bags. The company’s new VAC 95+ fully-recyclable bag has been certified by the ‘Cyclos HTP Institute’ as being of the highest purity in the recycling class AAA. The newcomer’s recipe was developed in the company’s own laboratories and advanced application technology centre. The new PP bag from Allfo can easily be identified and recycled without any additional costly recyclable separation required. The demand for recyclable vacuum bags is not only increasing in Germany. Other European countries are also influenced by the many EU directives that aim to reduce the amount of waste in many different ways. In Europe, 25.8 million tons of plastic waste are generated every year. To date, less than 30 percent of this is collected for recycling. According to the EU’s ambitious goals, by 2030, all plastic packaging placed on the EU market should be reusable or cost-effectively recycled.
“ we are already ten years ahead of the competition ” Ten years ahead Harrold Gessinger, Allfo’s sales manager, told SPN, “As Europe’s market leader for vacuum bags, we can proudly say that with our new fully recyclable bag, we are already ten years ahead of the competition in meeting this latest legislation. Customers do not have to fear any loss of quality either, because our new VAC 95+ range of bags does the same as classic PA / PE bags. This means that it is characterised by a high-performance barrier layer, that reliably protects food from moisture, dirt or unwanted ingress of oxygen. The quality of the VAC 95+ is already a clear indicator of its sustainability, because the CO 2 footprint in the production of food is much higher than that in the manufacturing process of vacuum bags. Any spoilage would therefore be a greater loss. In addition, the new VAC 95+ also outclasses others with its optimal sealing properties.
For further details visit www.allfo.de
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Recyclability
Higher yields - less waste
Minimising food waste
It is predicted that there will be a major surge in consumer demand as the year moves out of the Covid 19 pandemic. However there will also be increasing penalties for those who do not meet the new regulatory recycling standards. The Plastic Packaging Tax will see importers and manufacturers paying £200 per ton on all packaging materials that are made from plastic that is less than 30% recyclable. Just a few weeks ago, John Garner the head of business development for packaging at Antalis offered a mix of realism and optimism when looking ahead.
Flexible retort packaging is a modern alternative to metal cans, and it can improve the carbon footprint of hundreds of consumer products thanks to its light weight, resource efficiency, ease of transportation and by minimising food waste. Adding recyclability to its list of properties will further improve the environmental footprint of this packaging solution by around a further 60%.*
“ For many Antalis customers, packaging film is one of the biggest contributors to their plastic waste ” For many Antalis customers, packaging film is one of the biggest contributors to their plastic waste. So the company is looking at finding ways that will help them reduce their customer’s waste through achieving better yields. In addition Antalis will be continuing its research into other options. “We are currently looking at a solution using recycled film. First indications are very promising, so we shall be looking to progress this research throughout 20121 along with our on-going investigations into nano-films”.
Creating a world first Congratulations to Amcor who in collaboration with Nestle has recently launched the world’s first recyclable and flexible retort pouch. This new high-barrier pouch uses Amcor’s’AmLite & HeatFlex’ recyclable solutions. Amcor and Nestlé partnered to overcome one of the biggest challenges facing the industry; the inability to recycle retort flexible packaging, and have achieved a technological breakthrough which underscores both companies’ long-term commitment to more sustainable packaging solutions. The partners collaborated during the product development process, testing for heat resistance, machine performance, shelf-life and recyclability in the real world. “Amcor and Nestlé together have been able to create a unique solution that for years was thought impossible,” says Michael Zacka, President Amcor Flexibles EMEA, “This high-barrier, high-heat resistant, packaging can be easily recycled within plastic recycling streams already existing in several European countries.”
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The new pouch meets the packaging guidelines for a circular economy recently published by the Ceflex Consortium. Project Coordinator and Work-stream Consultant for Ceflex, Graham Houlder, says, “This is a great example of how innovation can solve even the biggest challenges facing recyclability. Recyclable retort packaging is a revolutionary advance and will have a huge impact in pet food and beyond.” With the promise of an end in sight to the Covid 19 pandemic, thanks to the approval of new vaccines, the Packaging industry can benefit from not only the increases in efficiency that they implemented during the lockdown, but can also look forward to a major bounce in consumer demand energising sales.
Recyclability
No Sceptics for aseptics! Les Fayes dairy in France has launched the first and only aseptic carton made from 100% renewable materials. Developed by SIG, a leading systems provider for aseptic carton packaging, the new aseptic carton has been developed exclusively by SIG in partnership with its customers in order to bring to bring food and beverage products to consumers from around the world in a safe, sustainable and affordable way. Founded in 1853, SIG is headquartered in Neuhausen, Switzerland and in 2019 produced more than 38 billion sustainable cartons that in turn generated almost €2 billion in revenue. The organic UHT milk from the La Laiterie Les Fayes cooperative in France is a subsidiary of the Terra Lacta group, which has adopted SIG’s awardwinning SIGnature 100 aseptic packaging.
“ companies are achieving much when it comes to innovation and a commitment to sustainability and the circular economy ”
ECO FRIENDLY FILMS AND BAGS ECO FRIENDLY FILMS AND BAGS
The company’s commercial director, Johnny Grippon, told SPN, “We are constantly looking for ways to improve our environmental impact and by partnering with SIG to launch our organic UHT milk we have taken a big step forward in reducing the impact of our cartons.
“ We are constantly looking for ways to improve our environmental impact ” The new SIGnature 100 for our Limousin organic milk fits perfectly with our brand and our commitment to the planet” Like all SIG carton packs it is fully recyclable and made from 100% recycled cardboard. It is always interesting to evaluate what is happening at different ends of the packaging spectrum and there can be no greater contrast than that between the CocaCola company and Erdbar, a new start-up company based in Germany. Both companies are achieving much when it comes to innovation and a commitment to sustainability and the circular economy.
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EcoCortec, Bele BeleBartoka Bartoka29, 29, 31000 31000Beli BeliManastir, Manastir, Croatia EcoCortec, Phone: +385 (0)31 705 011 Fax: +385 (0)31 705 705 012 Phone: +385 (0)31 705 011 Fax:Beli +385 (0)31 012 EcoCortec, Bele Bartoka 29, 31000 31000 Beli Manastir, EcoCortec, Bele Bartoka 29, Manastir, Croatia Phone: +385 (0)31 705 011 Fax: +385 (0)31 705 012
Eco Wrap®: World’s First Compostable Industrial Strength Eco Wrap®: Machine Grade Stretch Film! World’s First Compostable Industrial Strength Machine Grade Stretch Film! Eco Wrap®, the world’s first compostable industrial strength machine
grade stretch film, is here! The latest formula uses a certified Eco Wrap®, the world’s first compostable industrial strength machine compostable resin plus a tackifier additive to make an industrial grade stretch film, is here! The latest formula uses a certified strength compostable stretch wrap that can be used on standard compostable resin plus a tackifier additive to make an industrial automated stretch wrap equipment. strength compostable stretch wrap that can be used on standard automated stretch wrap equipment. This is a breakthrough for the industrial packaging industries which rely heavily on automated stretch wrapping to prepare pallets of This is a breakthrough for the industrial packaging industries which goods for storage, inventory, or shipment. Film users can benefit rely heavily on automated stretch wrapping to prepare pallets of from material/waste reduction in the following ways. First, most goods for storage, inventory, or shipment. Film users can benefit applications requiring three wraps of standard film can use two wraps from material/waste reduction in the following ways. First, most of Eco Wrap® without sacrificing strength or protection. Second, Eco applications requiring three wraps of standard film can use two wraps Wrap® is commercially compostable* according to ASTM D6400. of Eco Wrap® without sacrificing strength or protection. Second, Eco It may allow its users to avoid tariffs, fines, and tip fees in areas Wrap® is commercially compostable* according to ASTM D6400. where polyethylene is prohibited. Film is shelf and curb stable and It may allow its users to avoid tariffs, fines, and tip fees in areas will retain its integrity until disposed of properly. where polyethylene is prohibited. Film is shelf and curb stable and will retain its integrity until disposed of properly.