Circularity for Plastic Packaging
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Sustainable Packaging Systems Circularity design guide for plastic packaging Introduction Contents Packaging protects and preserves food and consumer goods products and gives a platform to inform the consumer about the product. Specifically, plastic packaging provides product durability, flexibility in design, hygiene and safety properties and can extend shelf life. However, following rising public concern about the rise in plastic waste, inconsistencies with collection and recycling facilities in the UK, and the increase of marine pollution, consumers are asking retailers and brands to minimise use and dependency on plastic. Whether you’re a senior technologist on a mission, an operations manager responding to client demands or a buyer with targets, this IGD guide will: • Talk you through the key sustainable design principles • Give you a 5 step design approach • Provide supporting insights and action points 2 SUSTAINABLE SUSTAINABLE 3 PACKAGING PACKAGING SYSTEMS SYSTEMS Understanding circularity Moving to a circular economy and the waste hierarchy Resources The plastics life cycle currently follows a predominantly The Ellen MacArthur Foundation’s Circular Economy Butterfly linear model that follows the path of raw material extraction, Diagram gives a useful structure to adopt circularity within Minimise Manufacture manufacture, product design and moulding, product use and sustainable design focused on: then disposal. As part of industry initiatives and commitments Remove Reprocessed/ recycled material such as the UK Plastics Pact, the aim is to ensure that where • Remove – eliminating unnecessary packaging Reduce Design plastic is used a circular approach is adopted. • Reduce – using less packaging such as light-weighting Recycle content • Reuse – using the same material over and over e.g. multi- Circularity aims to keep the resources in use for as long as use bags, refillable containers, reusable coffee cups possible–extracting its maximum value through maximum use/ Optimise 3 - Recycle reuse. It then encourages the effective collection and sorting • Recycle and use recycled material– segregating, collecting 1 - Minimise/ and sorting used packaging. Increase the amount of share/prolong of used material, recycling and remoulding (the adoption of Reuse Use recycled plastic content in new products over the use of virgin recycled content used (avoiding virgin materials) Recycle 2 - Reuse/ plastic). refill Prepare Leakage End of use/ Waste management recovery waste 4 SUSTAINABLE SUSTAINABLE 5 PACKAGING PACKAGING SYSTEMS SYSTEMS Industry ambitions Five step plan Sustainable Design Principles The food and consumer goods industry has responded by setting commitments around plastic reduction and dependency on plastic, increasing recyclability and recoverability of packaging, increasing reuse When designing the most appropriate packaging solution to and adopting circular economy principles. protect the product, it’s important to ensure that it’s designed in a way that reduces its environmental–both waste and The UK Plastics Pact is an initiative launched by WRAP and the Ellen carbon–impact. Decisions should be made based on its whole MacArthur Foundation that tackles the issue of plastic waste in the UK. 70% life cycle (source, type, usability and recyclability). This is known as the ‘cradle to cradle’ approach. The Pact brings together stakeholders involved in making, using, Nearly 70% collecting, sorting, reusing and recycling plastics in order to transform of UK plastic The Guide enables you to ask the following key questions at the system; agreeing collectively to: waste is from each step: 1. Eliminate problematic or unnecessary single-use packaging through packaging* redesign, innovation or alternative delivery model 2. 100% of plastics packaging to be reusable, recyclable or compostable 3. 70% of plastics packaging effectively recycled/composted 4. 30% average recycled content across plastic packaging An associated roadmap has been developed to support members to achieve these targets by outlining key activities that could be taken by all parts of the supply chain. At each of these phases, it’s important to question whether there are any potential unintended consequences. 6 SUSTAINABLE *WRAP SUSTAINABLE 7 PACKAGING PACKAGING SYSTEMS SYSTEMS Developing a packaging inventory will help Action notes to assess current plastics usage. Complete an inventory of your packaging products, Identify where you can have scope and opportunity to change, identifying: prioritise based on risk and produce a strategy or action plan. • Where plastics are used and in what format The packaging inventory should include a list of your plastic • Their recyclability and recovery performance (refer packaging products (start with highest volume where you have to Step 5) significant quantities). Then list polymer type(s), add major • Whether they include any ‘problem plastics’ for elimination or review constituents (e.g. plastic on card, plastic on plastic, plastic on metal foil etc.), followed by a recyclability review. Prioritise based on risk, client requirements and develop a strategy and/or action plan. Assess your Review your inventory against the 8 ‘problem’ plastics that will be eliminated as part of the UK Plastics Pact commitments, Remember to include questioning for unintended including single use disposal plastic cutlery, cotton buds with consequences within your strategy such as reducing plastic stems, plastic stirrers and plastic straws. shelf life, increasing food waste or carbon footprint, or plastic use creating recycling challenges. Note that there are a further 19 more ‘problem’ plastics being actively investigated to test viability of their continued use. These include single use drinks bottles, non-detectable black plastic packaging that’s not readily picked up in the recycling 8 problem plastics process, and a range of flexible plastics and films in everyday use. A full list is available from WRAP. Focus on these for action 1. Disposable plastic cutlery areas in the next steps. 2. All polystyrene packaging 3. Cotton buds with plastic stems 4. Plastic stirrers 5. Plastic straws 6. Oxo-degradables that break down to create microplastics 7. PVC packaging 8. Disposable plastic plates and bowls 8 SUSTAINABLE SUSTAINABLE 9 PACKAGING PACKAGING SYSTEMS SYSTEMS Identify opportunities to remove or reduce Action notes the amount of unnecessary plastic material. Check for unintended consequences, such as removing Using your inventory, review whether any of the following packaging not increasing food waste and the lighter sustainable design considerations work without affecting the the packaging, the more easily it can be littered (blown suitability of the packaging to protect the product: away). Be careful not to create new problems for our environment by switching to other materials without Remove packaging: Can the packaging be removed? E.g. on proper research, testing and evaluation of potential produce items or removing an outer layer or multipack film– consequences. For example: and focus on price points. • Switching to aluminium has higher carbon Remove and Light-weighting: Can the plastic be made lighter? This will lead implications to less material and support commercial saving programmes. • Compostables must have an appropriate collection and reprocessing system at point of disposal Smaller pack sizes: Can the packaging be made smaller whilst • Biodegradables have varying qualities and reduce plastic still serving its purpose? Focus on smarter branding approaches timeframes and improved store display and stacking. Note that oxo-degradables, which break down to create Identify alternatives to plastic: Would another packaging microplastics, will be banned by 2021 and should not be in design material be more sustainable and work just as well? Ensure used. whole life cycle–cradle to cradle approach is considered, including environmental risks and carbon emissions. Increase concentration: Review whether you can make your products more concentrated, or even solid. This reduces the amount of packaging needed and may make the technical requirements of the packaging less demanding. 10 SUSTAINABLE SUSTAINABLE 11 PACKAGING PACKAGING SYSTEMS SYSTEMS One of the main concerns about plastic Action notes packaging is that it’s only used once and thrown away. Identify where reuse solutions could be developed and adopted. Consult with trade bodies, retail, grocery Reuse models, enabled by technologies and shifting user and food-to-go teams to discuss current initiatives and preferences, can unlock significant benefits and has a higher trials. See if you can be part of these if relevant. circularity loop than recycling. Such models can help to deliver superior user experience, customise products to individual Check whether you can produce a refill version. Consult needs, gather user insights, build brand loyalty and optimise with trade bodies, etc, for initiatives in this area to align operations. with market-wide standards. Reusability There is no one size fits all option for new reusable/refillable packaging that will be applicable to every company, product or geography. Identify whether your product(s) has the potential The Ellen MacArthur Reuse Guide to support a returnable, refillable or reusable solution. This highlights 4 reuse models: could include removing single use bags, in store and online refillable homecare and dried products, food-to-go returnable Refill at home Return from home 1 2 and reusable containers, ‘naked’ produce, and reusable