Post on 24-Apr-2020
Packaging Best Practice Workshop
4 July 2013 WRAP and Spirit Pub Company
Welcome and Action Plan Updates Simon Drury Supply Chain Partnership Manager
Agenda
13.00 – 13.10 Welcome
13.10 – 13.40 Background, context and optimisation strategies
13.40 – 13.50 Task 1: Design Basics
13.50 – 14.05 Case Studies – The Bigger Picture
14.05 – 14.30 Task 2: Packaging in the Supply Chain
14.30 – 14.45 ‘Green’ Packaging: The Marketing Potential
14.45 – 15.15 Task 3: Opportunities and Barriers
15.15 – 15.30 Summary and Q&A
Background, context and optimisation basics Jenni Donato Packaging Specialist
WRAP - Our priorities Business Plan period (2011-2015)
Minimising resource use in products and buildings
Diverting priority materials from landfill
Hospitality and Food Service Voluntary Agreement
HaFS targets
Reduce packaging and food waste by 5% by 2015
Increase recycling to 70% in the sector
Resource Efficiency – what is it?
A definition of Resource Efficiency: ‘The efficient use of materials in design and construction’
Environmental Financial Social
Now included in EU’s Waste
Framework Directive.
Makes it a legal requirement to
consider the waste hierarchy when
dealing with waste
Resource Efficiency and the waste hierarchy
Carbon footprint of carrier bags
http://www.europackaging.co.uk/ecommerce/carbon.pdf
The primary function of packaging
... is to protect the product
Will people buy anything from the way it’s packaged?
In 2010, an artist set out to prove the value of packaging by packaging up rubbish he found on the streets of New York.
He sold over 1200 to 25 countries.
The value of packaging
80% of the cost of product set at the design stage
93% of production materials not used in the final product
80% of products discarded after a single use
Over 70% of the influence (of the environmental impact) is set at the design stage - this only takes 5%
of the overall cost of product development
How to start - the influence of design
For every £100 spent solving a problem in production
And £1 in design
The influence of design and money
It would have cost £10 in development
The easiest way to optimise your packaging is to think about it from a life-cycle perspective.
where did the raw materials come from?
what happens during the manufacturing?
how does it protect the product?
how is everything transported?
what impact does it have in use?
how is it disposed?
Only then can you assess the biggest environmental impacts and consider how to minimise this through good design.
Packaging Optimisation and life-cycle thinking
How do you measure improvements ?
Life-cycle Assessment?
Water footprinting ? Carbon footprinting?
Visible Waste ?
Packaging – a legal requirement
The Packaging Essential Requirement Regulations
Among others, this makes it a legal requirement to minimise weights and volumes of packaging
Enforced by Trading Standards Officers
Packaging Waste (Producer Responsibility) Regulations
You pay for the waste you’re responsible for – less waste, less cost!
Packaging ‘eco’ labels
Optimisation Strategies
Focus on size of packaging vs. product
Thickness of gauge of materials
The number of different
components and materials
Minimisation
2 litre bottle: reduced by 10.5% to 38.5g
500ml bottle: reduced by 17.9% to 19.7g
250ml bottle: reduced by 20.5% to 14.7g
Minimisation
Recyclability
Focus on segregation
Simple materials
Links to infrastructure in country of choice
Recycled content
Increasing the level of recycled content
Aluminium – 95% less energy use
PET – RPET – saving of 1.5 to 2 tonnes CO2e per tonne
Card – can put up weight by 25%
Concentration Why ship water around the world when it is
available at point of use?
smaller packages
fewer deliveries
need less storage space
can be applied to tablets / powders with fillers
Transport efficiency
Each bottle takes up
less space and is
stackable for
transport efficiency
They also collapse down
for transport efficiency on
the way back to the
recycling facility
Optimal Life eco-design strategy may include:
Product life extension
Longevity
Durability
Packaging – returnable / reusable
What is the payback period ?
Longevity
Embedded Carbon
Template optimisation
77 units 99 units
+28%
Second use
Definition of biodegradable ‘Capable of decaying through the action of living organisms’
Packaging terms and the consumer
Easy terms
Recycled, Recycled Content
Harder terms
Home compostable / Industrially compostable
Even harder terms
Bio-sourced / Biodegradable / Oxo-degradable
Pros Less waste Turns waste into a product Less demand for fossil fuels / raw materials / foreign oil Reduced cost of production
Cons Release of methane if it ends up in landfill Plants use valuable land Collection infrastructure Contaminants
1) What is the cost?
2) What is its function?
3) How is it stored / how long?
4) What will (realistically) happen to it at the end of its life?
BioPackaging Debate Continues
Task 1: Packaging Design Basics
Packaging Examples: Group discussion
What are its core functions? What are the materials, are they
appropriate for its application?
What has been designed well? What hasn’t?
How could you improve it using the optimisation strategies
just discussed?
In the short / medium term (low cost)
In the longer term (blue sky)
Packaging and the bigger picture
The bigger picture – going back to the life cycle
Bigger picture: Case study examples
Drinks company: in-house bottle blowing Looking at lifecycle – realised they were
shipping around empty bottles
Implemented in-house bottle blowing
Reduced transport requirements
Reduced packaging
Reduced storage space
Reduced costs
Stretch wrap – Yeo Valley
Saves 3,950 rolls per year
The machine paid for itself within 12 months
It has also avoided 24 tonnes of waste creation per year for customers
Home Depot - Slip sheets
Traditionally the wooden pallet and the fork lift truck
Weigh about 5% of a wooden pallet
Increase container capacity by up to 15%
Transport Efficiency
http://www.youtube.com/watch?v=
NuK-6KhkekU
http://www.riverfordenvironment.co.uk/Packaging.aspx
Riverford Organic Veg
“Packaging makes up a staggering 17% of our carbon footprint” “85% of our packaging
footprint is made up of paper and cardboard yet our customers are very happy with this packaging; virtually all negative comments on packaging relate to plastic punnets and bags which contribute only 8% to the footprint”
Belkin
Paper: 18,160kg of savings
Plastic: 2,480 kg of savings
CO2 reduction: 104 tonnes
Potential cost savings are in
excess of £700,000 per annum
After
Before
Kitchen Sink Packaging
What is your company doing because of development creep?
Lincoln and York Case Study
Supply Chain Partnership Case Study: Lincoln & York
Option of
implementing a
returnable packaging
system
Lincoln & York Case Study
Current system Single use cardboard boxes,
cost in excess of £20,000 per year.
Cost excludes tapes / labels / inner bag / packing material.
Cost also excludes waste disposal / recycling costs and PRN legislation costs.
Cost / Benefit Analysis
Proposed system
Purchase of used returnable plastic crates (working on a 2 week turn around), purchase cost less than £20,000
Payback period of less than 1 year. After the first year it’s nearly 100% cost saving!
Summary of benefits and savings
Even with additional costs of maintaining
float, washing, return transit, losses
Payback period is still just over a year
System will last for 20 years
Over 26 tonnes of card avoided
82 tonnes of CO2 equivalent saved
Waste Mapping refresher
To successfully minimise your wastes, you must understand where they are being produced.
Waste mapping will allow you to identify:
the types of waste you produce
where and why these wastes occur
the volumes and costs of waste produced
priority areas for action
Task 2: Packaging Supply Chain
Each group has some packaging
think about the supply chain
identify wastes areas along its supply chain related to the packaging design
Identify changes to the design to minimise these
Hospitality & Food service
Filling / Distribution
Manufacturing/ processing
Consumer
Raw Materials
‘Green’ Packaging: The marketing potential
Research by the co-op bank
The market for the green consumer grew by 15% in 2008
The market overall grew by 1.4%
Food up 14%,
Textiles up 71%,
Stationery up 49%,
even Funerals up 18%
Households spend an additional £707 per year
Green Consumer Market
Do something new...
Green consumers:
are sincere in their intentions, with a growing commitment to greener lifestyles;
almost always judge their environmental practices as inadequate;
do not expect companies to be perfect in order to be considered 'green‘
are not likely to forgive when they feel their trust has been broken
Getting it wrong
Avoiding Greenwash
What is Greenwash ?
“Presenting a product, service or company as
green, when it’s not - or there is no proof.”
Examples of Greenwash
Too selective
e.g. promoting a very limited green aspect (recyclability), whilst ignoring the wider environmental issues (virgin material)
Unclear e.g. saying something has recycled content when it’s only got minimal amounts and no effort has been made to increase it
Phantom comparisons
e.g. A new eco-shaped bottle that claims to now be 100% recyclable
when it was before
Distracting Some would say the green credentials distracts from the most eco-friendly way of drinking water – from the tap !
Unrealistic claims
e.g. a company with unrealistic targets, with no delivery plan,
simply used for marketing purposes
CARBON NEUTRAL
BY 2014 !
‘Greening’ dangerous product / Distracting
e.g. ‘Organic’ cigarettes distract the buyer from the dangers and impacts of smoking.
Pretend 3rd Party endorsements Products using terms / fake stamps like ‘Organic’ without any accreditation
GreenWash – caught and punished
Lexus forced to withdraw 3 adverts since 2007. Claims include ‘better for the environment‘
‘low emissions’ ‘zero guilt’
But none of the ads had any reference points
The backlash – if you get caught
Other ways to get it wrong
Retailer / Sustainability charity promotions
“We’re looking for volunteers to greet customers in stores to encourage their shoppers to buy additional items of food. We’ll then distribute the food to over 900 charities and community projects across the country for people in need. “
Task 3: Improvement Opportunities and barriers
Take one of your products, think of its supply chain, draw a process flow, consider what opportunities there are.
What barriers are there to implementing these?
Fill out your Action Plan Extension Forms with 5 steps for improvement.
Quiz: Good design or crazy designers?
Any questions?
Come along to the next session to uncover more opportunities....
Forthcoming technical workshops:
5 September 2013 AM – Energy and Carbon Management
5 September 2013 PM – Transport and Logistics
10 October 2013 – Behaviour Change
10 October 2013 – Water Efficiency
February 2014 – Project Dissemination Webinar
www.wrap.org.uk/spirit