Roadmap to sustainable packaging design
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Transcript of Roadmap to sustainable packaging design
9/30/2011
1
ROADMAP TO SUSTAINABLE PACKAGING DESIGN PROF. DR. IR. ROLAND TEN KLOOSTER
Packaging and Sustainability – starting points
Packaging is part of the chain and it fulfills an
important function
Loads in the chain are often unknown
Every packaging is sustainable because it protects the
product: lever function
Not one packaging is sustainable because every
packaging uses scarce sources (oil, gas)
Roadmap to Sustainable Packaging Design
Sustainability - approach
The best packaging is no packaging
This means: if you need a packaging, use it, but do it
as good as possible
Needed: insight in functions
Take care: the knowledge field of packaging is rather
unknown
Strategic choices have to be made and responsibility
has to be taken
Roadmap to Sustainable Packaging Design 4
Energy consumption – daily life (source Incpen)
5
Need for food – energy consumption - chain analysis
(Incpen)
6
Need for bread – energy consumption - chain analysis
(Incpen)
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7
Need for bread – energy consumption - chain analysis
(Incpen)
Roadmap to Sustainable Packaging Design
Need for ice – chain analysis
Carbon Foot Print Ben & Jerry's (Website B&J - 2008)
Sourcing of ingredients
(chocolate, fruit, cereals)
Energy needed for cooling
Dairy supply chain
Transport finished product
Packaging
Rest
Roadmap to Sustainable Packaging Design
LCA’s are tools
Some remarks
It’s all about the P from Planet
How about People and Profit?
Figures are not always right
Parts of the chain are rather unknown
Use phase is skipped
Human energy is not taken into account
Many LCA’s are not according to ISO
Roadmap to Sustainable Packaging Design
Sources for optimizing – viewpoint sustainability
Sustainable Packaging Coalition (Jedlička, W., 2009, pp 189-196).
Natural Step Framework (Jedlička, W., 2009, pp 197-200).
O2 International network for sustainable design, 5Rs (Jedlička, W., 2009, pp 200-
203).
Wall-Mart, 7Rs (Jedlička, W., 2009, pp 204-205).
Cradle to Cradle (Jedlička, W., 2009, pp 205-212).
EUROPEN (EUROPEN, May 2009).
Ecodesign, 10 golden rules (Lagerstedt, J., Luttrop, C., 2006).
Ecodesign checklist (Brezet, H., van Hemel, C., 1997).
Ecodesignweb (Lofthouse, V.A., August 2008).
Ecodesign handbook (Fuad-Luke, A., 2004)
Judith van Voorthuizen / Lenneke Koopmans / Jos de Lange / RtK
30-9-2011 Sustainability and Packaging 12
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Sustainability - approach
Three stages
Start up: Strategic choices have to be made
Development: In the design stage design choices are
being made about materials, dimensions, etc.
Life cycle: Finally is has to be executed
Roadmap to Sustainable Packaging Design Roadmap to Sustainable Packaging Design
STARTUP DEVELOPMENT LIFE CYCLE
Roadmap to Sustainable Packaging Design
STARTUP
Did you design a packaging with an understanding of the market it will be
sold in, and meet the consumer choice and expectation?
Benchmark existing packaging on the market.
Make a strategic choice based on the functions a packaging should and
can fulfil. Use the scheme of packaging functionalities.
Did you design a packaging that fulfils its functions efficiently?
Look at the triangle theory.
Roadmap to Sustainable Packaging Design
CHECKLIST 1
Product functionalities
Business Management
Design related
Functionalities of use
Packaging functionalities
Objective:
To be able to use
the product
Packaging costs Process costs
Way of use
Psychological
Design (styling)
Informing
Distributing
Conserving/
Protecting
More tactically based More strategically based
Societal
Politics
Regional/global
DESIGN
Roadmap to Sustainable Packaging Design
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Roadmap to Sustainable Packaging Design
DESIGN PROTECTING/CONSERVING
Proper packaging
design is statically
defined
Product
Vulnerability, type, taste, ingredients, components, etc.
Packaging
Material, thickness, shape, colour, structure, etc.
Kind of protection
Falling height, shelf life, temperature range, etc.
Roadmap to Sustainable Packaging Design
Roadmap to Sustainable Packaging Design
MAY FALL FROM 1,5 M WITHOUT PACKAGING
Roadmap to Sustainable Packaging Design
Roadmap to Sustainable Packaging Design Roadmap to Sustainable Packaging Design
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PROTECTING/CONSERVING
Proper packaging
design is statically
defined
Product
Vulnerability, type, taste, ingredients, components, etc.
Packaging
Material, thickness, shape, colour, structure, etc.
Protection
Falling height, shelf life, temperature range, etc.
Roadmap to Sustainable Packaging Design
Did you design packaging and product together to minimise the impact of
both?
Design methods: pv-combi
Use LCA tools if needed
Indicative: on base of weight, CO2 emissions, amount of MJ, amount of
waste, etc.
Roadmap to Sustainable Packaging Design
CHECKLIST 1
Did you design for modularity, combine functions or share use?
Functional specification, function hierarchy, idea generation techniques,
morphological mapping with functions
Did you design a packaging with the right sizes, which provides an
appropriate amount for the function?
Is the amount of product fitting for the market? Has research proven this?
Did you think in services (rent), not in products?
Define the function of the product. Ask yourself if the function can be
executed without a physical product.
Roadmap to Sustainable Packaging Design
CHECKLIST 1
Did you consider the use of refills/consumables?
A formula can proof if it makes sense to make a packaging reusable.
Aspects to take into account are: average travelling distance, energy for
cleaning/making the packaging reusable (think about new labels, new
caps, etc.), trip time, total investments
Did you select components with a classic styling for returnable
packaging?
Economic shelf life of products that are styled classic is longer.
Participation in a pool can be a solution as well.
Roadmap to Sustainable Packaging Design
CHECKLIST 1
Items to take into account
Transport distance
Cleaning energy
Cycle time
Pool dimension – number of items
Inter stack ability
Investments
Design and engineering
Roadmap to Sustainable Packaging Design
REUSABILITY
Did you eliminate or optimise primary or transport packaging through
design?
See the pallet as a system
Consider the combination of primary and secondary packaging
Roadmap to Sustainable Packaging Design
CHECKLIST 1
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Be sure choices on strategic level about packaging are being made
Try to optimize the way packaging fulfills its function
The briefing should be clear about this:
Design a packaging that …
Roadmap to Sustainable Packaging Design
BRIEFING
Roadmap to Sustainable Packaging Design
STARTUP DEVELOPMENT LIFE CYCLE
Roadmap to Sustainable Packaging Design
DEVELOPMENT
Roadmap to Sustainable Packaging Design
DEVELOPMENT
Roadmap to Sustainable Packaging Design
DEVELOPMENT
Roadmap to Sustainable Packaging Design
DEVELOPMENT
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Choice of materials Did you select materials with the lowest
environmental impact, while offering maximum performance for the
required task?
Lowest impact versus maximum performance
Consider differences in weight
Look for best practices as well
Did you select reusable, biodegradable or compostable materials?
Remind that all materials are reusable but the process to make them
reusable within the requirements set by the packaging function can be
complex. Many additives, colorants and inks contain toxic matter. This
makes reuse for food application in many occasions not possible.
Roadmap to Sustainable Packaging Design
CHECKLIST 2
Did you select materials with maximum recycling potential, which can be
recycled without quality loss (recycling or up cycling)?
Metals and glass can be recycled easily without quality loss. For paper
and board and plastics recycling means down cycling because fibres and
molecule chains are shortened because of the recycling process.
Did you select sustainably managed renewable or (continuously) recycled
source materials instead of primary materials?
Ask the material supplier after the percentage of recycled content in the
packaging material. Especially for secondary packaging the percentage
can be high (corrugated carton board, solid board, plastic crates). For
metals and glass the percentage of recycled material can be high. Metal
packaging can be made out of 100% recycled content, for glass the
quality for critical applications goes down if it is more than 50%.
Roadmap to Sustainable Packaging Design
CHECKLIST 2
Did you select materials with lower production energy levels, like
materials with a high recycled content?
The energy content of materials is expressed in MJ/kg (or GJ/ton). There
are key figures per material but for individual companies, differences can
be large. Take processing to packaging (box, bottle, can, cup, etc.) into
account and relate them to weight and compare the amount of MJ per
option.
Roadmap to Sustainable Packaging Design
CHECKLIST 2
Did you select safe and healthy materials and avoid hazardous/toxic
substances? If toxins are unavoidable, did you minimise the amounts and
use closed loops?
Toxic materials influence a LCA for a great deal. Try to determine if toxic
materials are being used. Especially watch additives, colorants and inks.
Many bright colours contain toxic matter.
Did you optimise all remaining problematic ingredients or materials?
Use as less as possible. Did you do testing or did you look for research
reports on this subject to minimize the amount?
Roadmap to Sustainable Packaging Design
CHECKLIST 2
Recall in 2009
because of 4 methyl-
benzophenone from
high gloss UV
lacquer
Roadmap to Sustainable Packaging Design
2002
Roadmap to Sustainable Packaging Design
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Did you optimize the number of materials being used?
Did you optimize the seize, weight, thickness of chosen materials?
Did you design for disassembly and recyclability? Are components easily
separable, especially hazardous components?
Did you design graphics to increase recycling rates?
Did you replace metals or metal layers for barriers with materials that
require less energy and pollution?
Did you maximise material strength, create minimal structures by using
compression, tension and triangulation?
Roadmap to Sustainable Packaging Design
CHECKLIST 2
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CONSTRUCTION
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OPTIMAL DIMENSIONS
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DIMENSIONS
Did you label material type, source and recycle fraction?
Did you invest in materials to reduce maintenance and prolong life? Did
you select the best suppliers, and check with them in the design process?
Did you select a supplier that practices green chemistry?
Did you use materials extracted from nature, because they tend to be
low-embodied-energy materials? Techno sphere materials have much
higher embodied-energy values.
Roadmap to Sustainable Packaging Design
CHECKLIST 2
Roadmap to Sustainable Packaging Design
DEVELOPMENT
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Roadmap to Sustainable Packaging Design
DEVELOPMENT
Did you optimize distribution of the packed product?
Did you fully use the surface of the pallet?
Did you use the collomodule system?
Did you do an analysis of the load in the chain on the product and/or
packaging?
Did you choose the best construction of the secondary packaging?
Did you choose the best materials for the secondary packaging?
Roadmap to Sustainable Packaging Design
CHECKLIST 3
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OPTIMAL PALLET LOAD
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Roadmap to Sustainable Packaging Design
DEVELOPMENT
Roadmap to Sustainable Packaging Design
DEVELOPMENT
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Did you consider the graphic design in relation to the printing technique of
all the items?
Colors are very critical, depending on the printing process. Check and
double check this before printing. Print a test series.
Did you consider the graphic design in relation to the packaging process?
Labeling or folding can cause a packaging which is not very nice because
small details can influence the image of the packaging. Be sure the
packaging design has been checked with the chosen materials and
construction.
Roadmap to Sustainable Packaging Design
CHECKLIST 4
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COLOURS OF SLEEVES AND CAPS
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INFLUENCE OF GRAPHICS
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INFLUENCE OF GRAPHICS
59
Barcode fully accross the bottom
Roadmap to Sustainable Packaging Design
STARTUP DEVELOPMENT LIFE CYCLE
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Roadmap to Sustainable Packaging Design
LIFE CYCLE
Did you optimize the packaging for use in the chain?
Do you separate the different materials?
Do you collect data about damage?
Do you recycle there were it is possible?
Do you inform customers about the made choices?
Roadmap to Sustainable Packaging Design
CHECKLIST 5
Did you consider the technical as well as the aesthetic lifetime of the
packaging?
Did you promote long life through possibilities for maintenance, repair,
upgrading? Did you prearrange this by labelling, manuals, form and
material use?
Did you reuse materials/components (recycling is mostly down cycling)?
Did you recover the material efficiently? Did you create well defined plans
for the disposal of the packaging (for returnables as well)?
Did you design a take-back program for packages to increase recycling
rates? Did you give an incentive to return the packaging: rebates,
recognition, and rewards?
Roadmap to Sustainable Packaging Design
CHECKLIST 5
Did you characterise energy, water, and resource consumption, and their
sources? Did you identify the contents of all components at 100 ppm
level?
Did you minimise the ecological footprint of the packaging and minimise
the energy, water, and resource consumption?
Did you select renewable energy sources instead of fossil fuels?
Did you select local materials and recourses (lower transport energy)?
Did you meet the emission standards and improve post-production air
and water quality to be as good or better than pre-production?
Did you increase energy efficiency within processes and ecosystems?
Roadmap to Sustainable Packaging Design
CHECKLIST 5
Did you minimise the number of production and assembly steps?
Did you minimise the number of parts and joining elements?
Did you select the most environment friendly production processes (e.g.
clean production technologies, minimise waste, air and water pollution)?
Did you select collomodule system dimensions for most efficient use of
transport space?
Did you select a reusable or recyclable transport packaging?
Did you select the most environmental friendly transport type and did you
consider the return journey as well?
Did you reduce the transport weight and/or volume?
Did you reduce the transport distance?
Roadmap to Sustainable Packaging Design
CHECKLIST 5
Are all packaging components suitable for the proposed disposal type,
including inks, surface treatments, additives, fillers, adhesives, and
more?
Did you prevent overdesign: close the loop? Closed-loop recycling
significantly reduces environmental impacts.
Did you communicate disassembly instructions clearly?
Did you test the package to confirm biodegradability, including all
components (add-ons, printing) and did you check the infrastructure for
composting?
Roadmap to Sustainable Packaging Design
CHECKLIST 6
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Did you examine the economic health, environmental restoration, social
equity?
Did you collect data about sustainable development, manage the
sustainable development, and publish the results in the public domain?
Did you meet the market criteria for performance and cost?
Did you examine the impacts on people in the supply chain?
Did you confirm if the supplier labour and trade practices match with
company?
Roadmap to Sustainable Packaging Design
CHECKLIST 7
Design the packaging in stages
Strategic choices are starting points
Be sure the product is protected/conserved well enough
Make a balance between different options (calculations
Optimize for distribution
Then make the final decisions about printing techniques and colours
Make appointments in the chain
Check if commitments will be fulfilled
Roadmap to Sustainable Packaging Design
HOW TO MAKE A COMPROMISE?
Packaging is a profession
May be investment in knowledge about packaging and packaging design
(engineering) processes is the most sustainable solution
Roadmap to Sustainable Packaging Design
CONCLUDING REMARKS
THANK YOUR FOR YOUR ATTENTION