Sustainability in Packaging    

Montserrat  Cas+llo  Owner  &  Consultant  at  RepaQ  Packaging  Consul+ng  

+34629310468  mcas+llo@repaq.es  

 

CONTENTS

SUSTAINABILITY  &  PACKAGING    LEGAL  SITUATION:  Considera6ons  on  Direc6ve  94/62/CE    IDENTIFICATION  OF  “HOT  POINTS”  ON  PACKAGING  SUPPLY  CHAIN  Analizing  packaging  func+onality    SUSTAINABLE  SOLUTION  /  INNOVATION  (3R)  Material  category  purchasing  management  Material  Re-­‐engineering  Process  Re-­‐engineering  Eco  design    

1  

PACKAGING AND SUSTAINABILITY

SUSTAINABILITY:  "Sustainable  development  is  development  that  meets  the  needs  of  the  present  without  compromising  the  ability  of  future  genera+ons  to  meet  their  own  needs.  It  contains  within  it  two  key  concepts:the  concept  of  'needs',  in  par+cular  the  essen+al  needs  of  the  world's  poor,  to  which  overriding  priority  should  be  given;  and  the  idea  of  limita+ons  imposed  by  the  state  of  technology  and  social  organiza+on  on  the  environment's  ability  to  meet  present  and  future  needs."    Our  Common  Future,  Brundtland  Comission  1987  

 PACKAGING:  Packaging  is  defined  in  the  regula+ons  as  "all  products  made  of  

any  materials  of  any  nature  to  be  used  for  the  containment,  protec+on,  handling,  delivery  and  preserva+on  of  goods  from  the  producer  to  the  user  or  consumer."  

2  

…  but  once  packaging  performes  its  func6on,  then  it  becomes  waste      

3  

SUSTAINABILITY OBJECTIVE: ENVIRONMENTAL COMMITMENT & BUSINESS

STRATEGY

4  

EXCESS PACKAGING

Think about… cost of packaging vs cost of product throughing out waste packaging

5  

OVER PACKAGING

Think about… cost of air transport?

6  

NON FUNCTIONAL PACKAGING

Think about… easy open? Or frustating? a good buy, add value? Repeat it, promote repeat

purchase?

7  

PACKAGING FEATURES An  ESSENTIAL    element  to    CONTAIN    PROTECT    PRESENT  

the  manufactured/commercialized  product  And  to  MINIMIZE  the  “a`er  use”  waste  

Sustainable/Responsible Packaging is optimized to reach 100% features

8  

CONTENTS

SUSTAINABILITY  &  PACKAGING    LEGAL  SITUATION:  Considera;ons  on  Direc;ve  94/62/CE    IDENTIFICATION  OF  “HOT  POINTS”  ON  PACKAGING  SUPPLY  CHAIN  Analizing  packaging  func+onality    SUSTAINABLE  SOLUTION  /  INNOVATION  (3R)  Material  category  purchasing  management  Material  Re-­‐engineering  Process  Re-­‐engineering  Eco  design    

9  

PACKAGING WASTE: EUROPEAN LEGISLATION

•  DIRECTIVE  94/62/CE  for  PACKAGING  AND  PACKAGING  WASTE  •  DIRECTIVE  2004/12/CE  (modifica6on  of  94/62/CE)    •  DIRECTIVE  2005/20/CE  (modifica6on  of  94/62/CE)  •  COMISSION  DECISION:    

–  97/129/CE  (Material  iden+fica+on)  –  2005/270/CE  (Data  base)  –  97/622/CEE  (report  D  91/692)  –  2005/270/CE  (raw  material  on  plas+c  transport  elements)  –  2005/270/CE  (raw  material  on  glass  packaging)  

 

10  

OBJECTIVES OF EUROPEAN PACKAGING DIRECTIVE

11  

The Member States must introduce systems for the return and/or collection of used packaging to attain the following targets: Ø by no later than 30 June 2001, between 50 and 65% by weight of packaging waste to be recovered or incinerated at waste incineration plants with energy recovery; Ø by no later than 31 December 2008, at least 60% by weight of packaging waste to be recovered or incinerated at waste incineration plants with energy recovery; Ø by no later than 30 June 2001, between 25 and 45% by weight of the totality of packaging materials contained in packaging waste to be recycled (with a minimum of 15% by weight for each packaging material); Ø by no later than 31 December 2008, between 55 and 80% by weight of packaging waste to be recycled; Ø no later than 31 December 2008 the following targets for materials contained in packaging waste must be attained:60% for glass, paper and board;50% for metals;22.5% for plastics and;15% for wood.

TRANSPOSITION OF EUROPEAN PACKAGING DIRECTIVE

12  

Austria Packaging Ordinance of 1992, amended 29th November 1996 Target Ordinance (Federal Law Gazette No. 646/1992, as amended by 649/1996)

Belgium The Ecotax-Act (ordinary Law of 16th July 1993 aiming at completing the federal structure of the State) Interregional Co-operation agreement Packaging Decree of 30th of May 1996 (came into effect on 5th March 1997) Law of 21st December 1998 (essential requirements) The Royal Decree of the 25th of March 1999 defining standards for packaging.

Denmark Statutory Order no. 298 of 30 April 1997 on certain requirements for packaging Statutory Order no. 299 of 30 April 1997 on waste Statutory Order no. 124 of February 27, 1989 on packaging for beer and soft drinks as amended by statutory order no. 540 of 1991 and no. 583 of 1996 and no. 300 of 30 April 1997

Finland Decision of Council of State on Packaging and Packaging Waste 1997 Law on Alcohol Excise, No. 1471 of 29th December 1994 Law on Soft Drinks Excise, No. 1474 of 29th December 1994

France Lalonde Decree N° 92-377 of April 1 1992, in force since January 1993, setting out conditions for the collection and the recovery of packaging waste produced in households. Decree N° 94-609 of 13 July 1994 on packaging waste for which the holders are not households. Decree N° 96-1008 on the disposal of household waste which contains the quotas set by the European Packaging Directive Decree N° 98-638 of 20 July 1998 related to the environmental requirements in the design and manufacture of packaging

Germany Packaging Ordinance of 1991, amended 21st of August 1998

Greece Draft Law "Measures and conditions for the alternative management of packaging and other waste products. Foundation of the National Organisation for the Alternative Management of Packaging and Other Waste (NOAMPOW)"

Ireland Waste Management (Packaging) Regulations 1997 Waste Management (Farm Plastics) Regulations 1997 Waste Management (Packaging Amendment) Regulations 1998 Source:

European Commission DGXI.E.3 European Packaging Waste Management Systems Final Report February 2001

TRANSPOSITION OF EUROPEAN PACKAGING DIRECTIVE

13  

Italy "Ronchi Decree", Law effective from 5th Feb. 1997 implementing EC Directives (Directive on waste, hazardous waste and packaging waste)

amended 28th Nov. 1997

Luxembourg Grand Ducal Regulation of 31st October 1998

Portugal Decree-Law No. 366-A/97 of 20th December 1997 (modified by Decree-Law N° 162/2000 of 27th July 2000) Ordinance N° 29-B/98 of January 1998 The Decree-Law N° 407/98 of 21 December 1998 for essential requirements and maximal concentration of heavy metal

Spain Packaging Law 11/1997 of 24th April 1997 Royal Decree 782/98 of 30th April 1998 Law 10/1998 of April 21st 1998 Order 50/1998 of 30th December 1998

Sweden Decree (1997 - 185) on producer responsibility for packaging.

TheNetherlands Packaging and Packaging Waste Decree of July 4th 1997 Packaging Covenant II of 26 December 1997

UK Producer Responsibility Obligations (Packaging Waste) Regulations 1997 Packaging Regulation (1998) Packaging (Essential Requirements) Regulations 1998 Producer Responsibility Obligations (Packaging Waste) Regulations (Northern Ireland) 1999

Source: European Commission DGXI.E.3 European Packaging Waste Management Systems Final Report February 2001

BUSSINESS PREVENTION PLAN •  What  is  it?  Organiza6on  commitment  to  reduce  and  improve  quality  of  

packaging  waste.    •  What  is  for?  The  main  objec6ve  is  to  minimize  amount  of  packaging  waste  

•  Who?  Economic  operators  must  plan  and  implement  a  bussiness  preven6on  plan  if  they  place  into  market  more  than:            MATERIAL      Tm.  /year            Glass        250            Steel        50            Aluminium      30            Plas6c        21            Wood        16            Cartonboard      14            Other        350  

         

   

14  

BUSSINESS PREVENTION PLAN GOAL   MEASURE   INDICATOR/CONTROL  

15  

CONTENTS

SUSTAINABILITY  &  PACKAGING    LEGAL  SITUATION:  Considera6ons  on  Direc6ve  94/62/CE    IDENTIFICATION  OF  “HOT  POINTS”  ON  PACKAGING  SUPPLY  CHAIN  Analizing  packaging  func6onality    SUSTAINABLE  SOLUTION  /  INNOVATION  (3R)  Material  category  purchasing  management  Material  Re-­‐engineering  Process  Re-­‐engineering  Eco  design    

16  

CPP ANALYSIS

Analysis  of  packaging  func+onality  enables  to:    

–  Define/Design  packaging  adapted  to  its  Contain,  Protect,  Present  requirements  

–  Grade  of  achievement  of  CPP  requirements  for  already  exis+ng  packaging  

DEFINE  OBJECTIVES  

17  

CPP ANALYSIS

CONTAIN  Packing  facility  

PROTECT  Transport  

PRESENT  Retail  /  Final  customer  

X  =>   X   X  X   X  

X  X  

=>  =>   X   X  

X  X  

X  

18  

CPP DATA MANAGEMENT <=  PRO

DUCT

S   CONTENT   PROTECT   PRESENT  

Material  1ari  

Process  

…   Packing   Transport   Acond.   … Waste   Lineal  …  

M1  

M2  

M3..  

P1   P2…  

…   E1   E2   E3   T1  

T2  

T3  

C1   C2   … PAP  

PL   VID  

PD1  

PD2  

…  

19  

STEPS FOR CPP ANALYSIS

1.-­‐  Data  compila+on  2.-­‐  Data  management      Indicator  parameter-­‐s  defini+on.  

3.-­‐  CPP  data  matrix  4.-­‐  Conclusion    Iden+fica+on  of  improvement  items  

20  

STEP1: EXAMPLE OF CPP ANALYSIS

21  

STEP2,3: EXAMPLE OF CPP ANALYSIS

22  

STEP2,3: EXAMPLE OF CPP ANALYSIS

23  

STEP4: CONCLUSIONS OF CPP ANALYSIS •  OPTIMIZATION  of  PRODUCT  –  MATERIAL  –  PROCESS  

           CONCLUSION  IMPROVEMENT  BY    Product  vs  Material  =>  OK    =>  Alterna+ve  supplier-­‐s  /  Category  Purchasing  Management  

         =>  KO    =>  Material  re-­‐engineering,  alterna+ve  material    Material  vs  Process  =>  OK    =>  ✓  

         =>  KO    =>  Material  re-­‐engineering,  alterna+ve  material  for                      produc+vity  improvement                    Process  re-­‐engineering  

24  

CONTENTS

SUSTAINABILITY  &  PACKAGING    LEGAL  SITUATION:  Considera6ons  on  Direc6ve  94/62/CE    IDENTIFICATION  OF  “HOT  POINTS”  ON  PACKAGING  SUPPLY  CHAIN  Analizing  packaging  func+onality    SUSTAINABLE  SOLUTION  /  INNOVATION  (3R)  Material  category  purchasing  management  Material  Re-­‐engineering  Process  Re-­‐engineering  Eco  design    

25  

CASE STUDY 1: NON FUNCTIONAL PACKING

26  

•  Clima+c  condi+ons  (RH,  T…)  •  Palle+za+on  Plan  (cross,  ver+cal  stacked)  •  Palle+za+on  Height    •  Load  characteris+cs  (self  suppor+ng,  fragile…)  •  Distribu+on  cycle  •  Transport  type  (truck,  ship,  plane…)  •  Transport  box  format  and  dimensions  •  Maximum  Sta+c  Load  Resistance  •  ….    

PACKING OPTIMIZATION: STRUCTURAL DESIGN GUIDE

Safety factor => BCT,  ECT  27  

28  

# of referencesDe

Composition ECT (kN/m)

309269 BFB 111B 3 0,34% -15,35%

309271 B110P95B110 3 0,50% -3,67%

309272 B110P95B110 3 0,06% -3,67%

309282 B4-SQ3-B4 3 0,14% -3,67%

309287 B120P100B120 3 0,20% -3,67%309288 B100F100B100 3 0,03% -3,67%309945 BFB 3 0,03% -3,67%313046 BFB 3 0,06% -6,59%313458 BFB 3 0,06% -15,35%309375 BFB 3 0,06% -3,67%312968 BFB 3 0,06% 17,05%312877 BB130F100B100 3 0,09% -6,59%313394 BBFB 3 0,14% 8,01%312617 BBFB 3 0,14% 17,05%312755 BB125F95B110 3 0,22% -6,59%313047 BB130F100B100 3 0,34% 8,01%311459 TB160SQ150T180 3 0,39% 17,05%313288 BBFB 3 0,67% 8,01%310036 BB130F100B100 3 0,84% -3,67%312846 BB130F100B100 3 1,21% 17,05%313589 BFB 3 1,68% -6,59%309380 BFB 3 1,68% -3,67%310978 BB130F100B100 3 1,99% 8,01%311069 BB130F100B100 3 1,99% 17,05%312865 B100F100B100 3 3,06% -6,59%313376 B100F100B100 3 5,64% 5,09%311753 B100F100B100 3 5,64% 5,09%313534 BBFBB 3 6,73% -6,59%309378 BBFBB 3 6,73% -3,67%313640 BBFB 3 0,50% 8,01%313367 BB130F100B100 3 0,08% 2,17%313367 B110F95B110 3 0,48% -15,35%313367 BB125F105B110 3 1,40% -15,35%311658 B130F100B130 4 0,21% -9,97%313648 B130F100B130 4 0,34% -3,47%311749 B130F100B130 4 0,34% 0,28%313137 KBFK 4 0,34% 0,28%311752 KBFK 4 0,67% 0,28%309268 T7M6T7 4 1,07% 2,53%309267 T7M6T7 4 3,22% 2,53%312687 T7M6T7 4 13,48% 7,53%310118 KB5-P4-B4 5 0,06% 3,36%313367 KB140S130T170 5 0,23% 0,10%313457 KB5-P4-B4 5 0,31% 0,10%312956 KB5-P4-B4 5 0,31% 0,60%309289 KB5-P4-B4 5 0,31% 0,35%309275 BTE8-P4-BET8 5 0,35% 7,87%311368 TB160SQ150T180 5 0,39% -4,67%313588 TB160SQ150T180 5 0,84% -0,91%309276 BET8-P4-BET8 5 1,11% -3,16%313441 KB140F100B100 5 1,21% 5,36%310217 KB5-P4-B4 5 1,40% -7,18%310308 KB5-P4-B4 5 1,40% 5,36%313415 KB5-P4-B4 5 13,48% -7,18%309284 T8SQ8T7 6 0,50% -8,51%312526 1

2 T8SQ8T7 6 1,29% -2,13%

312596 6 8,87% -10,64%311661 K7-SQ5-K7 8 0,73% 4,26%311662 K7-SQ5-K7 8 0,20% 17,02%311446 K7-SQ5-K7 8 2,08% 2,13%311537 K7-SQ5-K7 8 2,08% -2,13%

D % coste medio/m2

% Volum anual

29  

PACKING PURCHASING

30  

•  Material  Category  Defini+on  Material  Category  is  defined  as  a  group  of  references  suitable  for  a  

common  management.  They  use  to  share  material  quality,  manufacturing  process,  supplier,  market…  

•  Nego+a+on  for  each  Material  Category  •  I.e.  Nego+a+on  of  corrugated  transport  box  in  terms  of  ECT,  

process,  prin+ng,  volum…    =>  change  from  purchasing  boxes  to  purchasing  different  quality  

corrugated  carton  sheet  =>  cri+cal  factor  for  purchasing:  cost/m2  

MATERIAL CATEGORY MANAGEMENT FOR PURCHASING

31  

CASE STUDY 2: PACKAGING MATERIAL RE-ENGINEERING

•  CPP  Analysis  =>  Significant  impact  in  refrigera+on  process  –  Product:  200g  dairy  desert    –  Primary  packaging:  PP  container  +  lid  –  Secondary  packaging:  corrugated  carton  box  for  12  units    

•  Suitability  analysis:  –  Product  vs  2nd  Pack  =>  OK,  composi+on  is  adjusted  to  required  BCT  –  2nd  Pack  vs  Refrigera+on  Process  =>  KO  (theoric  5s  =>  2ºC,  actually  10s  =>  

5ºC)  

 

Op+miza+on  of  refrigera+on  channel  formed  in  the  box    

32  

48mm   103mm  

57,5   40  

25mm  40mm  

50mm  

INITIAL  (350x180x125mm)  

REFRIGERATION  HOLES:  Dimensions:  40xh20mm  Posi+on:  according  to  plan  

57,5   40   57,5  

2xformatge  fresc  1,8  Kg              6xiogurt500g  

RE-ENGINEERING OF PACKAGING MATERIAL

48mm   98mm  

76  

78mm  

40mm  

Alterna+ve  1  (350x180x125mm)  

40  

   2xformatge  fresc  1,8  Kg            6xiogurt500g  

Alternta+ve  2  (292x196x125mm)  

60  

REFRIGERATION  HOLES:  Dimensions:  40xh20mm  Posi+on:  according  to  plan  

RE-ENGINEERING OF PACKAGING MATERIAL

CASE STUDY 3: PROCESS & MATERIAL RE-ENGINEERING

•  CPP    Analysis  =>  Significant  impact  in  pasteuriza+on  process  –  Product:  cooked  meat  product  (barbacued  ribs)  –  Primary  packaging:  PA/PE  film  for  thermoforming  –  Secondary  packaging:  folding  carton  +  corrugated  carton  transport  box  

•  Suitability  analysis:  –  Product  vs  1st  Pack  =>  OK  –  1st  Pack  vs  Process  =>  OK  for  pasteuriza+on,  KO  for  steriliza+on    

 Thermal  process  op+miza+on,  changing  to  suitable  material  for  new  

process  condi+ons    

35  

36  

PROCESS & MATERIAL RE-ENGINEERING

PROGRAMA  10  

FASE:6                        TIEMPO:  2h  55  min  TIEMPO   Tª   PRESION  

25   90   750  140   90   750  2   70   500  2   50   400  2   45   300  4   40   0  

PROGRAMA  11  

FASE:  6                      TIEMPO:  57  min  TIEMPO   Tª   PRESION  

35   110   900  10   110   900  2   90   700  2   70   500  3   50   300  5   40   0  

Film PA/PE Film PP/PA/PE

37  

CASE STUDY 4: PACKAGING PROCESS RE-ENGINEERING

•  Product:  Mayonnaise  900g  •  Primary  packaging:  PP  bucket  1200cc  +  flexible  lid  +  rigid  lid  •  Packaging  system:  fill+  seal+  close  25  env/min    

38  

PACKAGING PROCESS RE-ENGINEERING

Product: Maionesa 900g Primary packaging: flexible film for stand up pouch Packaging system: FFS 300 env/min

39  

ECO-EFFICIENCY Reduce  /  Recycle  /  Re-­‐use  =>  Minimiza+on  of  waste  on  the  way  to  the    

             Sustainable  packaging  

40  

REDUCE BY DIMENSIONAL OPTIMIZATION

   •  Kr/Kp  op+miza+on,  minimiza+on  of  free  space  

Applica+on  example:      

•  8% less material +bigger savings in added components of the supply chain => reduction of air space in the inner bag => reduction of the packaging size without decreasing the amount of food •  The new compact packaging also allows for more efficient use of retailer space and enables retailers to [fit] a wider variety of products [on store shelves]

41  

RE-USE, RECYCLE

Product:  100%  natural  –  no  preserva+ves    Packaging  materials:    

 PET  –  60%  recycled    PLA  -­‐  compostable  

42  

ECO-DESIGN What  is  eco-­‐design?  

 Eco-­‐design  means  considering  Environment  as  one  more  factor  when  developing  or  re-­‐designing  some  product  

.              

   

 The  objec6ve  of  eco-­‐design  is  to  minimize  environmental  impact  in  the  whole  Life  Cycle  of  the  developing  product.  

             

   

Product  design  

Environment  Ergonomics  

Quality  

Safety  Func+onality  

Cost  

Ste+cs  

43  

ECODESIGN AND LIFE CYCLE

44  

LIFE CYCLE ANALYSIS

45  

ECO-DESIGN

Source:  Tuboplast  Hispania  46  

ECODESIGN

Source:  Tuboplast  Hispania  

• Raw  material  consump+on  reduc+on  (33%)  • Increasing  produc+vity  (40%  reduc+on  forma+on  cycle  +me)  • Energy  consump+on  reduc+on  (38%)  • Waste  reduc+on  (12%)   47  

THANK  YOU  FOR  YOUR  ATTENTION!!              

Montserrat  Cas+llo  Owner  &  Consultant  at  RepaQ  Packaging  Consul+ng  

+34629310468  mcas+llo@repaq.es  

www.montsecas+llo.com  /  www.repaq.es  Linkedin:  hxp://es.linkedin.com/in/montsecas+llo  

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