Waste Management A Packaging Perspective


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  • Legislation impacts if you have Turnover greater than 1 million IRP Produce more than 25 tonnes of packaging (input & output) Brown Thomas example. -Used to self comply, now in Repak Really only one option now. -Recycling is only part of the process
  • Data collection and analysis is time consuming Targets for recycling are easier met with group approach.
  • IBL database for packaging specifications This is matched to sales figures for each 6 months The amount of packaging material (per type) can then be calculated. IBL system is based on queries and macros in the database.
  • Since the Repak Uplift scheme was cancelled, the funding for this now goes towards subsidising re-cycling initiatives by members and partners of Repak. We have dealt with people outside the Repak loop, but have told them there are rebates available if they join Repak. It also makes it easier for us if they join as it is easier to follow the audit trail if they are members of Repak which ensures that material sent for re-cycling is re-cycled.
  • Food Waste -Dough (In process re-cycling) -Dry Biscuit (Batch re-cycled) -Processed Biscuit (Animal food) Packaging Waste Input Packaging (All packaging around what we take in) Output Packaging (All packaging around what we make) E.g. Pallet of Cases input: stretchwrap, wooden pallet etc. Output Cases WIP (Generally dry biscuit and cream/jam containers)
  • Goods Inwards Bulk Material: No packaging Palletised : Bags: Some contaminated, some recyclable Minor: Colours/Flavours. All contaminated but can be incinerated in Germany Packaging: No waste produced here at this stage Factory Produced: Input packaging: i.e packaging around packaging Output packaging: Waste cases, wrapper etc. Warehouse/Shipping: Picking pallets means stretchwrap is taken off as well as spare pallets being left.
  • We have gone from a situation where we used to split food and packaging waste to where we now must split our packaging into 7 subsections. Cardboard is split into corrugated and non corrugated (Mainly because the non corrugated is heavily printed) Plastic is also split into recyclable and non recyclable (This used to be rigid and flexible)
  • Apart from waste management, All of the above points make good economic sense. 1. -Good initial design 2. -Advances in material technology 3. -Developing choices with suppliers (e.g.SCC) 4. -Will customers take more packs in an outer? (e.g. Cash and Carry) 5. -Is the pallet volume used? (Double stacking etc)
  • Returnable containers: -Depends on good relationship with suppliers -Three way relationship: -container manufacturer -packaging manufacturer -customer (us!) -Can be problems with storage and segregation of returnable containers Test board in outer cases: -All cases are now a mix of virgin/recycled material -Inner liners and flutings nearly all test -Outer liners Kraft, but some Test -Outer cases treated as new material by Repak -Heavier Test liner than Kraft liner required for same strength -Plateau reached by substituting material as it then costs more. Pallets -Inverted onto plastic pallets on factory floor -Using more and more CHEP pallets
  • -Used Repak Uplift scheme in 2000 -Sourced our own contractors since Uplift scheme was abolished. -Work with contractors for best solution -Storage and segregation is an issue (e.g. plastic reels Trafford/Sloan) -Continue to try and consolidate material usage -Cartonboard/Corrugate -Flexibles pvdc etc. -Approved contractor scheme with Repak provides traceability for recycling
  • We are already designing packaging so that it will be suitable for incineration if it happens in Ireland. This scheme is already in place for colours/flavours suppliers. Product (and packaging) is incinerated in Germany.
  • Landfill is Last Resort. May not be an option soon. Used when material is -contaminated -unsegregated -not suitable for re-cycling (e.g. wet cardboard) Landfill costs continue to rise It is getting easier all the time to justify recycling equipment Some of the costs involved: Container charges Removal charges Waste contractor management charges Repak levies Your time manageing and reporting on this.
  • As can be seen from the above slide, we still have opportunities to divert more material from landfill.
  • This slide shows that while there are opportunities for Irish Biscuits to divert material from landfill, anything we do to reduce the amount of packaging going into the marketplace will have a much more significant impact.
  • Holistic projects Project for 2003: 1. Change shape of tray for product with min. weight and min. gauge (One tray will replace three thus lowering inventory and input packaging) 2. Change wrappers and cases so that pallet utilisation is optimised. (Increase of up to 40% in some cases)
  • (Point 4) Emphasis on ‘individually packed’, ‘Ready to Go’ implies more packaging per product. Danone use ‘grams of packaging per 100g of product’. We are consistently less than 10g of packaging which is one of the best in Danone, but need to watch new products. Up to now, these products have not had major volume for us. As opposed to this, now getting more customer queries on environmental impact of our packaging. We provide marketing with details of the advances we have made in regard to the environmental impact of our packaging.
  • Waste Management A Packaging Perspective

    1. 1. Waste Management(A Packaging Perspective) Colm Munnelly Packaging Technologist Irish Biscuits Ltd. December 2002
    2. 2. Who are Irish Biscuits?• IBL formed in 1966 by merger of Jacobs (1851) and Bolands Biscuits (1957)• Employ over 600 people• Manufacture over 50 types of biscuit• Turnover circa 100,000,000 euro
    3. 3. Packaging Waste legislation• Waste Management (Packaging) Regulations 1997: (“Designed to assist and promote the recycling of packaging waste” -SDCC) • Two Real Options: – 1. Comply with the legislation independently and report to the local authority. – 2. Participate in a Waste recovery scheme operated by an approved body (Repak)
    4. 4. 1. Legislation Requirements:• Provide information on annual turnover• Provide information on location of premises• Provide information on weights of packaging materials• Display notices• Provide facilities to accept, collect packaging waste• Return waste to suppliers• Recover or make waste available for recovery• Prepare, publish plans and reports• Submit information monthly to local authority
    5. 5. 2. Obligations of Repak Membership:• Provide data on packaging material twice a year to Repak• Pay invoices• Join Green Dot scheme• Deal responsibly with waste• Inform Repak of changes to systems• Allow system to be audited for Repak
    6. 6. Advantages of Repak Membership:• Obligations complied with as a group• Green Dot membership• Approved Contractor Scheme (Rebates)• Audit chain for each contractor
    7. 7. Sources of Physical Waste at IBL• Food Waste – Dough – Dry Biscuits – Processed Biscuits (with Cream/Chocolate/Mallow)• Packaging Waste – Input Packaging – Output Packaging – WIP (Work in Progress)
    8. 8. Sources of Packaging Waste• Goods Inwards – Bulk Material – Palletised Ingredients – Minor Ingredients – Packaging• Factory Produced – Input Packaging – Output Packaging• Warehouse / Shipping – Pallets – Stretchwrap
    9. 9. Packaging Material Types• Cardboard Corrugate, Cartonboard etc.• Paper Liners, Inserts, Menu Pads• Flexible Plastic Film Wrapper Reels• Other Plastic Tubs, Trays• Metal Tins• Glass Bottles• Wood Pallets
    10. 10. Waste Hierarchy Reduction / Minimisation Re-use Re-cycle Reclaim Landfill
    11. 11. 1. Reduction / Minimisation• 1. Reduction of input packaging• 2. Gauge reduction on film, trays, tins, tub• 3. Reduction of outer case board grades• 4. Increased number of packs per outer case• 5. Pallet volume optimisation
    12. 12. 2. Re-use• Returnable containers for trays, tubs• Increased use of Recycled (Test) board in outer cases• Maximum usage of pallets (Increased use of CHEP) (wooden for goods outward) (plastic on factory floor)
    13. 13. 3. Re-cycle• Corrugated Cardboard Smurfit Re-cycling• Cartonboard Smurfit Re-cycling• Flexible film Dilloan Recycling• Other plastic Re-Tech Processing/Dilloan• Metal Hammond Lane• Glass (Negligible amounts)• Wood Pallet Services
    14. 14. 4. Reclaim• Awaiting options for incineration• Input packaging on colours/flavours• Removal of pvc and pvdc material
    15. 15. 5. Landfill• Compacted, unsegregated waste from the factory floor goes to landfill through Ipodec• Any material left that does not have a re- cycling option is landfilled.• Cost of landfill (Direct and Indirect)
    16. 16. Internal Packaging Waste 250 200Tonnes 150 100 50 0 Total Internal waste Waste to Landfill Internal Waste Management
    17. 17. ‘Repak Member of the Year’• Packaging waste considered at product design stage• Emphasis on Reduction and Re-use• Sourced re-cycling options for all of our packaging materials• Encouraged contractors to join subsidy scheme• Reduced tonnage to landfill by 10% in 2001
    18. 18. Packaging Fees 3500 3000 2500Tonnes 2000 1500 1000 500 0 Input Internal Output Output Packaging Waste Export Ireland Type of Packaging
    19. 19. What winning has meant to IBL• Turns Repak into something positive• Recognition for past efforts• Establishes momentum• Helps overcome ‘difficult’areas• Helps publicise re-cycling efforts throughout the company.
    20. 20. Future plans in IBL• Further investment in bailing/compacting• Roll out of recycling to more ‘difficult’ areas• Design for recoverable/recyclable packaging• Holistic projects – Less input packaging – Optimum product in packets – Optimum packets in cases – Optimum cases on pallets
    21. 21. Challenges• Options to recycle in Ireland and to market recycled product in Ireland.• Current weight based system does not allow for mixes of virgin/recycled material.• Recycled material does not mean cheaper material.• Conflict between marketing concerns and environmental concerns.