Sustainex 2013 - Packaging Design Regulations Robert Duncan (PDF)


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Sustainex 2013 - Packaging Design Regulations Robert Duncan (PDF)

  1. 1. Sustainex Packaging WorkshopRobert DuncanSenior Environmental ConsultantNorthern Ireland Science Park, Belfast028 90 78 73 78
  2. 2. Workshop agenda•  Packaging in your business•  How packaging impacts on your businessand the environment•  Eco-design principles/ considerations•  Principles in practice/ opportunities•  Barriers and solutions•  Q&A sessionExercises throughout – think about YOURbusiness
  3. 3. What exactly is resourceefficiency?•  It is about sustainable management and useof resources throughout their life cycle -from extraction, transport, transformation, consumptionto the disposal of waste.•  It means producing more value with lessmaterial and consuming differently, to limit the riskslinked with scarcity and for less environmentalimpacts, within our planet’s natural limits.
  4. 4. And how does this relate topackaging?•  Considering eco-design principles•  Optimising packaging use•  Selecting more sustainable materials•  Reducing packaging waste•  Complying with packaging Regulations=> Cost savings for your organisation.
  5. 5. Levels of packaging…Consider the total packaging system•  Primary packaging - the pack thatthe consumer takes home.•  Secondary packaging - innercartons, trays, boxes. Thisincludes retail-ready and displaypackaging.•  Tertiary packaging - the outertransport packaging, such aspallets and stretch wrap, that getsproducts to the depot ordistribution centre.
  6. 6. Packaging in your BusinessPrimary Packaging
  7. 7. Packaging in your businessSecondary Packaging
  8. 8. Packaging in your BusinessTertiary Packaging
  9. 9. Packaging in your business60 SECOND EXERCISEList what types and where packaging existsin your business
  10. 10. Packaging efficiency driversCost Savings•  Less material (weight/volume) costs less•  Reduced product loss/damage costs.•  Reduced incoming supplier packagingresults in reduced waste managementcosts.
  11. 11. Packaging efficiency driversSupply Chain Pressures•  Customers are requesting more efficient/sustainable/green/recyclable packagingmethods which business needs to adapt tocost effectively•  Show your commitment to sustainabilityand adapting to customer’s needs
  12. 12. Packaging efficiency driversLegislation•  Improved packaging efficiency, tracking and reporting ofpackaging consumption reduces legislative costs andliability– Producer responsibility obligations (packaging waste)Regulations– Packaging (Essential Requirements) RegulationsNon-compliance?...A stationery supplier was taken to court and fined because goodsordered through its website arrived in boxes which were only 7%,19% and 29% full.
  13. 13. Packaging efficiency driversMarketing•  Increase your company’s competitivenessin the marketplace•  Supporting your green credentials(ISO14001, Carbon Footprinting etc.)•  Good PR stories
  14. 14. Packaging efficiency driversLogistics•  Optimising processflows•  Maximisingtransport loads•  Minimisingwarehousing
  15. 15. Packaging efficiency driversEnvironmental•  Increasing % of recyclable materials used•  Reduce product wastage•  Reduced carbon footprint•  Reduce waste to landfill
  16. 16. How packaging impacts yourbusiness and the environment60 SECOND EXERCISEList your business drivers for and againstimproving packaging efficiency(choose specific examples)
  17. 17. Packaging eco-designprinciples•  Design for Minimisation•  Design for Reuse•  Design for Recycling•  Design for compostingThese principles will berelevant to you as;•  A customer•  A supplier•  An end-user•  A packer•  A filler•  A distributor
  18. 18. Fit for Purpose?...Remember why you use packaging…•  Ensure product arrives in good condition•  Protect the contents from hazards•  Easy to open•  Easy to carry•  Attractive to consumers
  19. 19. Design for Minimisation•  Essentially we are talking about…– Reduce packaging volume– Reduce packaging weight… to the minimum required to achievefunctional requirements (Fit for purpose).
  20. 20. Minimisation Considerations•  Could a change in product or packaging designallow a reduction in the size or weight of thepackaging while maintaining its capacity?•  Could less material be used by modifying thevolume sold, e.g. more sales units per box,larger portions, bulk or even loose?•  Could you reduce packaging by changing thephysical nature of the contents or by using analternative material?
  21. 21. Minimisation Considerations•  Are additional materials such as intermediatelayers, shrink wrap, adhesives and tapes allnecessary?•  Could the distribution system be modified in away that would reduce energy consumption orthe amount of packaging needed?•  Could certain components be strengthened orweakened to reduce overall material use?
  22. 22. Minimisation in Practise
  23. 23. Minimisation in PracticeBooker – U.K.’s leading food wholesaler•  Worked with supplier to reduce thickness of stretch wrap from17µm to 7µm whilst keeping the wrapping technique the same.•  A reduction in average film usage perpallet from 303g to 125g•  A reduction in annual film consumptionfrom 315t to 130t•  Carbon emission reductions of 500t/yr•  Greater than 50% saving in film cost•  Improved load consolidation• • 
  24. 24. Minimisation in PractiseOther minimisation opportunities•  Review light-weighting of all packaging(e.g. glass, plastic, cans, cartons etc.)•  Reducing corrugated cardboard thickness•  Removing unnecessary virgin layers,inserts or replacing with (otherwise)packaging waste.
  25. 25. Interesting…•  To package the same amount of coffee; needed aglass jar weighing 470g, a metal can weighing 120gor a laminate pack weighing 11g.•  The laminated pack was not recyclable, and afteruse all 11g remained for disposal. However, evenafter 80% recycling of the metal and glass – anunlikely scenario - there was far more material left(94g glass, 24g metal) for disposal from these twooptions than from the laminate.•  On top of the waste aspects, the heavier packsneeded three times the number of lorries to deliverthe same amount of coffee.
  26. 26. Minimisation Opportunities60 SECOND EXERCISEList what packaging minimisationopportunities may exist in YOUR business
  27. 27. Design for Reuse•  Essentially we are talking about…– design to minimise lifecycle impacts, e.g. bymaximising return rates.– design for ‘closed loop’ reuse in preference toan alternative use.… without compromising functionalrequirements (Fit for purpose!).
  28. 28. So what’s reusable?...•  Pallets•  Drums and intermediatebulk containers (IBCs)•  Crates, boxes and trays•  Separators, layer padsand collars•  Pallet boxes/systems•  Metal cages and stillages
  29. 29. Reuse Considerations•  Ensure that the packaging is designed for andis robust enough for re-use.•  Check that your business partners will alsotreat the packaging as re-usable and will returnit as appropriate, or that collectionarrangements are in place to enable privateend-users to return it.•  Additional storage space will likely be required.
  30. 30. Reuse Considerations•  Ensure that facilities for cleaning, repair orreconditioning are available if this is necessarybefore the packaging can be re-used.•  Obtain written confirmation from your supplierthat the packaging is capable of re-use, andconfirmation from your customers that theyintend to place the packaging into a re-usecircuit.
  31. 31. Reuse in PracticeInvest NI Client Example•  Swapped single usecardboard for reusableplastic crates•  Savings of £300,000reported and under a 2year project payback.
  32. 32. Reuse in PracticeInvest NI Client Example•  Returned high value,unrecyclable foamprotecting layer andplastic inserts back tolocal supplier•  Reduced landfill wastecosts and negotiateddiscount on product
  33. 33. Reuse in PracticeOther reuse opportunities•  Reusing incoming supplier packaging (e.g. boxes,crates etc.) for outgoing product dispatch•  Reusing incoming supplier packaging for internalmovement of product•  Store and reuse bubble wrap, air pockets etc.•  Engage frequent suppliers/customers to swap multipledeliveries of single use packaging with one combinedreusable packaging container•  Return secondary and tertiary packaging to supplier
  34. 34. Reuse Opportunities60 SECOND EXERCISEList what packaging reuse opportunities mayexist in YOUR business
  35. 35. Design for Recycling•  Essentially we are talking about…– specifying a material with an existing and widespreadsystem for recovery– if possible using only one material, if not usingmaterials which are easy for you/the consumer toseparate or do not contaminate recycling systems– Using the maximum amount of recycled content that’sphysically possible (preferably post-consumer).… without compromising functional requirements (Fit forpurpose!).
  36. 36. Recycling Considerations•  Try to avoid materials, combinations ofmaterials or designs of packaging that mightcreate problems in collecting, sorting orrecycling.•  Minimise the use of substances or materialsthat might create technical, environmental orhealth problems in the recycling process or inthe disposal of recycling residues.
  37. 37. Recycling Considerations•  Construct your packaging so that the end-user can easilyseparate any components that should not go into therecycling process (‘design for disassembly’).•  Can you have a policy for ‘recyclable’ single usepackaging only?•  Minimise the use of substances or materials that mighthave a negative influence on the quality of the recycledmaterial. For example, do you need a colour tint on yourplastic bottle or could you achieve the same effect withan eye-catching label?
  38. 38. Recycling in PracticeOther results were very positive:•  Cement in plastic bags is 39% moreenvironmentally-friendly than other solutions.•  14% less energy is required throughout thelifecycle of the plastic. Why is this? With plasticbags, there is less waste than with traditional bags.•  Its carbon footprint is also 45% less throughout theproducts lifecycle as plastic is more resistant toperforation, which avoids losses and waste of theproduct on suppliers premises and building sites.•  The reduction in product losses also leads to a fallof 81% in waste water and 52% in solid wastethroughout the lifecycle.Lafarge – World leader in building materials•  Changed traditional paper-plastic unrecyclable cement bag with arecyclable plastic bag
  39. 39. Recycling in Practice
  40. 40. Interesting…WRAP research on consumer attitudes towards purchasing goodspackaged in recycled plastic.
  41. 41. Design for Composting•  Essentially we are talking about…– specifying compostable rather than oxo-degradable materials– ensuring that a system is available forcollection and processing.… without compromising functionalrequirements (Fit for purpose!).
  42. 42. Composting Considerations•  Will your compostable packaging belighter or heavier than the packaging itreplaces?•  Will the use of biopolymers adverselyaffect the contents of your packaging?•  Clear and conspicuous labelling isessential to prevent it ending up in landfill!
  43. 43. Composting in Practice•  Quality Street twistwrappers are now madefrom a compostablematerial which comes froma renewable resource –wood-pulp from managedplantations.•  Fully compostablemushroom-based protectivepackaging will be used toship stand-up paddle surfboards from PUMA toretailers or directly to peoplewho order them online.
  44. 44. Interesting…
  45. 45. Recycling and CompostingOpportunities60 SECOND EXERCISEList what packaging recycling andcomposting opportunities may exist inYOUR business
  46. 46. Barriers to ImplementationBarrier 1.  Supplier and/orcustomer push-back2.  Lack of topmanagement buy-in3.  Lack of in-houseknowledgeSolution 1.  Communicate provencase studies2.  Produce a detailedbusiness case3.  Industry best practiceguidance or obtainsupport from Invest NI,packaging experts etc.
  47. 47. Barriers to ImplementationBarrier 4.  Fear of productdamage5.  Supplier can’tprovide alternative6.  Staff attitudestowards packagingwaste recyclingSolution 4.  Run a trial beforerolling out changes5.  Source newpackaging supplier6.  Making recycling theeasier option thangeneral waste bin
  48. 48. Want to learn more?...•  Envirowise PackGuide: A guide topackaging eco-design - GG908•  NI Business Info•  Industry Council for Packaging and theEnvironment -
  49. 49. Questions?Thank you for your time today.1-to-1 discussions available after thesession, just ask!OrGet in touch: