Innovative Solutions for Reusing Packaging Waste Materials in Humanitarian Logistics

sustainability

Article Innovative Solutions for Reusing Packaging Waste Materials in Humanitarian Logistics

Alberto Regattieri * ID , Mauro Gamberi, Marco Bortolini ID and Francesco Piana

Department of Industrial Engineering, Alma Mater Studiorum—University of Bologna, 40136 Bologna, Italy; [email protected] (M.G.); [email protected] (M.B.); [email protected] (F.P.) * Correspondence: [email protected]; Tel.: +39-(0)51-209-3400

Received: 18 April 2018; Accepted: 14 May 2018; Published: 16 May 2018

Abstract: The impact of packaging waste on the environment is becoming unsustainable, which has necessitated a turning point in material recycling and reuse. Such a concept is highly relevant in the humanitarian supply chain due to the huge mass of packaging items that are provided to countries hit by disasters, with these bad conditions making it almost impossible to adopt a rational management of waste streams. The goal of this study is to provide an approach and feasible solutions to reduce the environmental influence of waste produced by packaging and at the same time, to help people affected by disasters. Starting from the analysis of the available materials, several solutions of packaging reuse and recycling are developed and several prototypes are realized and tested in collaboration with the United Nations Humanitarian Response Depots-Lab (UNHRD-Lab), which starts from the basic packaging materials used to supply first-aid to people, including cardboard, pallets, woods, and plastics. This paper addresses the above ideas and presents the design process, results and some quality tests. The experimental evidence encourages future on-field validation in refugee camps.

Keywords: packaging material; humanitarian logistics; waste management; material reuse; recycling

1. Introduction Packaging is a big part of the daily materials that people handle and its function, aspect and role are changing due to innovations in the products and processes [1,2]. Packaging materials flow along the supply chain as the products themselves. Furthermore, they also fulfil logistic, marketing and safety requirements [3,4] when containing, storing, handling and shipping goods [5–9]. The literature classifies the following functions of packaging:

• to protect the product quality and properties during shipments [6,10–16]; • to protect the environment from product contamination and hazards [6,17–19]; • to convey information and brand communication attracting customers to choose a particular product [1,20–23]; and • to reduce the waste of products and losses [24–28].

Among the weaknesses coming from the massive use of packaging materials, their environmental impact is becoming unsustainable due to the raw resource use as well as the amount of CO2 emissions and environmental pollutants caused by their disposal and landﬁlling. Thus, the market has been encouraged to mitigate these environmental problems by designing packaging with sustainable materials and experimenting with new models and packing methods [29–31]. It is also important to study new strategies and approaches to optimize the treatment of packaging waste to improve global sustainability.

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Sustainability in packaging waste management has to match the most commonly applied definition of sustainable development, which was first proposed by the Brundtland Commission in 1987 [32] as the: ‘[ ... ] development that meets the needs of the present without compromising the ability of future generations to meet their own needs’. This definition involves addressing three principles of sustainability, which are namely economic, social and environmental [33]. This is strongly connected to the ‘triple P model’: people (of the developing countries), planet (the eco-systems) and prosperity (equal growth) [34]. From this perspective, packaging waste materials should no longer be considered as garbage but as materials with a potential [35] to be reused or recycled within a secondary lifecycle [36,37]. The introduced environmental problems related to the packaging materials are more evident in certain supply chains, such as the military, space exploration missions [38] and the supply chains associated with the humanitarian field. This paper addresses the packaging waste management within humanitarian logistics due to the increase in environmental and sustainability issues. When a disaster occurs, a large quantity of humanitarian items arrives in the disaster area to supply the basic needs of the population. After the product are unbundled, the packaging becomes waste immediately and it is collected in the surroundings and/or it is emptied roughly [39], which contributes to a crucial global sustainability problem. Having alternatives to tackle this problem is mandatory. With the aim of addressing this topic, the purpose and innovation of the study is two-fold: (1) to find easy and immediately applicable ways to minimize the environmental impact of the large amount of packaging waste created during emergency aids and (2) to help people affected by disasters, generating useful tools for their daily life from the reuse of the packaging waste. According to this purpose, the reminder of the paper is organized as follows. Section2 presents the adopted methodology and provides an overview of common packaging materials available in emergency contexts, while Section3 presents several prototypes of useful daily products coming from the packaging waste reuse together with their easy-to-assemble procedures. In addition, this section presents some quality tests developed together with the United Nations Humanitarian Response Depots-Lab (UNHRD-Lab), which joined this research. Finally, the conclusions and future research directions are in Section4.

2. Method and Materials This section presents the adopted methodology and input materials for facing the two-fold problem of treating the packaging waste materials in humanitarian camps and emergency areas and to provide aids to people living in extreme poverty that lack certain basic needs.

2.1. Method Figure1 proposes the methodology adopted in the present paper. Two study directions appear. On one hand, this involves the analysis of the current standard in humanitarian aids that ships tons of goods to the emergency areas and are responsible for most of the packaging waste materials. On the other hand, this include the investigation and prioritization of the basic needs of people living in such areas. Concerning the former direction, multiple humanitarian missions were analyzed with the aim of creating lists of shipped materials together with their standard packaging solutions. Such a list is directly correlated to the key streams of packaging waste materials that need to be managed in terms of variety and quantity. Concerning the latter direction, given the structure and facilities within humanitarian camps, an ordered list of basic needs to supply is provided, which forms the basis for conceiving the original reuses of packaging waste materials. Starting from the evidence of these two research directions, the generation, design, development, prototyping, lab-test and assessment of multiple solutions of secondary products generated from Sustainability 2018, 10, 1587 3 of 10

Sustainability 2018, 10, x FOR PEER REVIEW 3 of 10 packaging waste materials are conducted. These activities are within the boundaries of this research,while the whilefinal field the- ﬁnaltest and ﬁeld-test diffusion and of diffusion the most of promising the most solutions promising is solutionsamong the is forthcoming among the forthcomingactivities. activities.

FigureFigure 1.1. Schematic ofof thethe adoptedadopted methodology.methodology.

2.2. Input Materials 2.2. Input Materials According to the first study direction, we evaluated the quantity and variety of the packages According to the ﬁrst study direction, we evaluated the quantity and variety of the packages usually shipped by the humanitarian organizations to the staging areas and areas close to the usually shipped by the humanitarian organizations to the staging areas and areas close to the catastrophe strike places. In these areas, goods and equipment are stocked, sorted and distributed to catastrophe strike places. In these areas, goods and equipment are stocked, sorted and distributed people. to people. In collaboration with the UNHRD-Lab, we conducted a previous study [40] that examined the In collaboration with the UNHRD-Lab, we conducted a previous study [40] that examined the shipments during 2012 to determine the set of typical humanitarian aids and of most interest, to shipments during 2012 to determine the set of typical humanitarian aids and of most interest, to collect collect more than 100 packaging lists, which is essentially the list of packaging materials containing more than 100 packaging lists, which is essentially the list of packaging materials containing products, products, tools and other aids. Table 1 presents an extract of the analysis that classifies the packaging tools and other aids. Table1 presents an extract of the analysis that classiﬁes the packaging materials materials according to their nature for each list and the percentage of the packaging material mass according to their nature for each list and the percentage of the packaging material mass (PM) in the (PM) in the total gross mass (GM) in the last column. total gross mass (GM) in the last column.

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Table 1. Quantity and types of packaging materials for the selected packing lists [40].

List Id. Wooden Box [kg] Cardboard [kg] Steel Crate [kg] Plastic [kg] Pallet [kg] PM/GM [%] 1 - 102 720 - 20 10.00% 2 - - 360 - 40 4.78% 3 - - - - 60 0.84% 4 2320 592 200 1533 1302 19.21% 5 1421 344 200 33 1230 16.91% 6 - 24 120 - - 6.88% 7 594 1706 - 2500 2200 22.40% 8 - 640 - - - 6.50% ...... 109 200 - - - - 11.41% Total 4535 5328 1600 4066 5332 10.81%

The incidence of the packaging materials is about 10.81% of the total mass, which is proportional to the relevant costs to ship materials that become waste immediately after the product are unbundled. Local reuse and recycling of such packaging materials is of great interest from both economic and environmental perspectives. To this purpose, some materials are easier to reuse as pallets. Plastic and cardboard are not conceived to have an as-is reuse but they can be reshaped quite easily to create different items. Because of its large availability and versatility, this study focuses on cardboard from carton boxes as the material waste to reuse. Standard boxes are corrugated ﬁberboard boxes or regular slotted containers made with double wallboard ﬂute paper with a thickness of 5–7 mm. The thickness and the double wallboard make the cardboard very strong and easy to fold and bend without advanced tools.

2.3. Refugee Needs The needs of people in humanitarian camps and emergency areas are basic as they only require what is important for their survival and daily living. Past studies present the classiﬁcations of such needs starting from the micro-scale, such as the needs of the person, through the mid-scale, such as the needs of small groups of people as a family, to the large-scale, such as needs of the community living in the same area [40]. At all the three levels, the solutions are of great importance to guarantee acceptable living conditions, to prevent health risks, to preserve the living areas and to set the foundation for restarting normal living conditions. This study targets the micro- and mid-scale levels presenting and validating basic prototypes that are useful for the people and family everyday activities, such as moving items, sleeping, sitting, walking, etc. Section3 details these solutions, which we conceived and tested in partnership with the UNHRD-Lab.

3. Prototyping from Cardboard Packaging Waste Cardboard is one of the most used materials in the packaging of humanitarian items (see Table1). Double wallboard is a robust material with low weight, which is easy to handle and to cut. Thus, it can be used to obtain different types of equipment even by common people with raw working tools. Such conditions make this packaging waste material a good candidate to investigate.

3.1. Carton Backpack People living in an emergency camp often have to go to common areas that are usually far from their own accommodation to get food or other objects useful for their daily life. They normally do not have effective supports to transport food and other materials. Thus, we began by making a robust backpack from the reused cardboard boxes. Figure2 shows the design of the proposed backpack. Sustainability 10 Sustainability 20182018,, 10,, 1587x FOR PEER REVIEW 55 of 1010 Sustainability 2018, 10, x FOR PEER REVIEW 5 of 10

Figure 2. Design of proposed backpack. FigureFigure 2 2.. DesignDesign of of proposed proposed backpack backpack.. Using the proposed design and maintaining the same dimensional relations, it is possible to Using the proposed design and maintaining the same dimensional relations, it is possible to createUsing a backpack the proposed with an designappropriate and maintaining capacity and the payload. same dimensionalThis backpack relations, is simple it to is build possible and to it create a backpack with an appropriate capacity and payload. This backpack is simple to build and it createis design a backpacked and developed with an appropriate with reproducibility capacity and in payload.mind. Its This cons backpacktruction does is simple not require to build complex and it is is designed and developed with reproducibility in mind. Its construction does not require complex designedtools as it andonly developed needs a pair with of reproducibilityscissors, a simple in mind.knife and Its construction some packaging does tape. not require To help complex people toolswho tools as it only needs a pair of scissors, a simple knife and some packaging tape. To help people who aslive it in only humanitarian needs a pair refugee of scissors, camps, a simple it is possible knife and to some add some packaging packaging tape. Totape help in peoplethe relief who packs live so in live in humanitarian refugee camps, it is possible to add some packaging tape in the relief packs so humanitarianthat they can make refugee equipment camps, it for is possible themselves to add as presented some packaging here. Figure tape in 3 theshows relief the packs carton so backpack that they that they can make equipment for themselves as presented here. Figure 3 shows the carton backpack canthat makewas built equipment using reused for themselves packaging as from presented a kitchen here. set Figure usually3 shows shipped the cartonby UNHRD backpack in emergency that was that was built using reused packaging from a kitchen set usually shipped by UNHRD in emergency builtareas. using reused packaging from a kitchen set usually shipped by UNHRD in emergency areas. areas.

Figure 3.3. Carton backpack developed and tested using the packaging from a kitchen set provided by Figure 3. Carton backpack developed and tested using the packaging from a kitchen set provided by UNHRD toto thethe refugeesrefugees asas ﬁrstfirst aid.aid. UNHRD to the refugees as first aid. Carton backpack prototypes were tested with regard to payload, shock and damage resistance both CartonCarton backpack backpack prototypes prototypes were were tested tested with with regard regard to to payload, payload, shock shock and and damage damage resistance resistance both both in the Laboratory of Industrial Engineering, Bologna University and in the UNHRD-Lab. Th results were inin the the L Laboratoryaboratory of of Industrial Industrial Engineering Engineering,, Bologn Bolognaa University University and and in the in UNHRD the UNHRD-Lab.-Lab. Th results The results were encouraging. The backpack has a good capacity and an outstanding payload. For example, the backpack encouraging.were encouraging. The backpack The backpack has a good has capacity a good and capacity an outstanding and an outstanding payload. For payload.example, the For backpack example, in Figure 3 can hold 12 liters and up to 20 kg of payload for a long time in a dynamic environment with inthe Figure backpack 3 can inhold Figure 12 liters3 can and hold up 12to liters20 kg andof payload up to 20 for kg a long of payload time in fora dynamic a long time environment in a dynamic with hits. The breaking strength tests show that the carton backpack fails at an average load of 32.4 kg. This is henvironmentits. The breaking with strength hits. The tests breaking show that strength the carton tests backpack show that fails the at carton an average backpack load fails of 32 at.4 ankg. average This is an unexpectedly high result due to the backpack material being reused materials. anload unexpectedly of 32.4 kg. Thishigh isresult an unexpectedly due to the backpack high result material due to being the backpack reused materials material. being reused materials.

3.2. Carton Cradle 3.2. Carton Cradle Many infants live in refugee camps and require specialized equipment, such as cradles. The design ManyMany infants infants live live in in refugee refugee camps camps and and require require specialized specialized equipment, equipment, such such as as c cradles.radles. The The design design of a prototype of carton cradle (Figure 4) was developed, with a simple cradle structure using a joint ofof a a prototype prototype of of carton carton cradle cradle (Figure (Figure 4) was developed,developed, with a simple cradle structure using a joint framework. The dimensions of the cradle could be modified based on the age and size of the infant. framework.framework. The The dimensions dimensions of of the the cradle cradle could could be be modified modiﬁed based based on on the the age age and and size size of ofthe the infant infant..

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FFigureFigureigure 4.4 .4 C.Carton Cartonarton c cradle radlecradle design design. design. .

StartingStarting from from from a aa common commoncommon carton cartoncarton box, box, the the two two headboards headboards headboards and and and the the the two two two other other other rectangular rectangular rectangular sides sides sides of of theofthe the cradle cradle cradle are are aredrawn drawn drawn and and andcut. cut. cut.After After After attaching attaching attaching the the four four the sides foursides sidesof of the the ofcradle, cradle, the cradle, another another another rectangular rectangular rectangular carton carton wascartonwas cut cut was and and cut mounte andmounte mounteddd transvers transvers transverselyelyely to to become become to become a a mak mak a makeshifteshifteshift carton carton carton mattress. mattress. mattress. Figure Figure Figure 5 55 showssho showsws thethe the completedcompleted carton carton cradle. cradle.

FigureFigure 5 5. .5 Carton. Carton cradle cradle prototype. prototype.

TheThe carton carton cradle cradle prototype prototype is is tested tested with with regard regard to to its its payload,payload payload, ,which which showed showed a a resistance resistance up up toto 15 15 kg. kg. The The breaking breaking strength strength tests tests also also show show that that the the cradle cradle fails fails at at payloads payloads above above 22 22.6 22.6.6 kg kg due due to to thethe distortiondistortion distortion and and and failure failure failure of of theof the frame.the frame. frame. Finally, Finally, Finally, Figure Figure Figure4 shows 4 4 shows howshows the how how frame the the is frame designedframe is is designed withdesigned minimal with with minimalcomplexityminimal complexity complexity using joint using using connections. joint joint connections. connections. Additionally, Additionally, Additionally, this type of this this frame type type increases of of frame frame the increases increases breaking the the strength b brereakingaking of strengththestrength cradle. of of the the cradle. cradle.

3.3.3.3. Carton Carton Slippers Slippers TheThe majority majority majority of ofof people peoplepeople living living in in an an an emergency emergency emergency camp camp camp have have have to to towalk walk walk without without without any any any type type type of of shoes. ofshoes. shoes. To To Toroughlyroughly roughly solve solve solve this this thisproblem, problem, problem, a a pair pair a pairof of very very of verysimple simple simple slippers slippers slippers were were weredesigned designed designed using using using carton carton carton boxes. boxes. boxes. Two Two Twoversionsversions versions were were weredeveloped. developed. developed. T Thehe f ormerf Theormer former used used one usedone carton carton one carton-layer-layer-layer with with a withafoot foot profile a profile footproﬁle drawn drawn drawnonto onto the the onto carton carton the forcartonfor sizing. sizing. for sizing.To To create create To createthe the att att theachmentachment attachment for for the the for top top the of topof the the of foot thefoot, foot, ,a a carton carton a carton strip strip strip was was was drawn drawn drawn and and and attached attached attached to to thetothe the foot foot foot profile. profile. proﬁle. Finally, Finally, Finally, the the theslippers slippers slippers were were were covered covered covered with with with brown brown brown packaging packaging packaging tape. tape. tape. Brown Brown Brown packaging packaging packaging tape tape lendtapelends lends sstability stability stability to to slippers slippers to slippers and and and cover cover coverss sall all allthe the the shape shape shape,, ,making making making these these these slippers slippers slippers water water-resistant.water-resistant-resistant. .Figure FigureFigure 66 6 showsshows th this thisis version. version.

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Figure 6. One carton-layer slipper. Figure 6. One carton-layer slipper. Figure 6. One carton-layer slipper. The latter version used two carton layers to provide more robustness. Two mirrored foot profiles wereThe designed latter version on the carton. used two Additionally, carton layers in thisto provide provide case, to more morecreate r robustness.obustness. the attachment Two Two mirrored on the top foot of the profiles proﬁles foot, werea carton designed strip was on the drawn carton.. Finally, Additionally, the slippers in this were case, covered to create with the attachment brown tape on as the before top of . Figurethe foot, foot, 7 showsa cartoncarton this stripstrip vers was wasion drawn.. drawn Finally,. Finally, the the slippers slippers were were covered covered with with brown brown tape astape before. as before Figure. Figure7 shows 7 thisshows version. this version.

Figure 7. Two carton-layer slipper. Two carton-layer slipper. Figure 7 7.. Two carton-layer slipper. Moreover, to obtain more comfortable slippers, other layers of cardboard can be added to the Moreover, to obtain more comfortable slippers, other layers of cardboard can be added to the lowerMoreover, surface of to the obtain slipper more using comfortable brown tape slippers, as glue. other Cardboard layers ofis cardboarda good material can be for added this aim to the as itslower corrugate surface structure of the slipper is able using to adapt brown to the tape foot as andglue. the Cardboard ground. is a good material for this aim as lowerits corrugate surface structure of the slipper is able using to adapt brown to tapethe foot as glue. and the Cardboard ground. is a good material for this aim as its corrugate structure is able to adapt to the foot and the ground. 3.4. Carton Stool 3.4. Carton Stool 3.4. CartonAnother Stool useful object to help people in their everyday life coming from carton boxes is a small Another useful object to help people in their everyday life coming from carton boxes is a small stool.Another First, two useful covers object were to created help people using inthree their overlapped everyday lifecircular coming carton from layers. carton After boxes this is, a stool. First, two covers were created using three overlapped circular carton layers. After this, a cylindersmall stool. of cardboard First, two coverswith the were same created diameter using as threethe covers overlapped provided circular the vertical carton layers.height. AfterFinally, this, a cylinder of cardboard with the same diameter as the covers provided the vertical height. Finally, a lasta cylinder carton oftube cardboard prevented with the the collapse same diameter of the stool as the. Figure covers 8 shows provided the these components, vertical height. which Finally, are last carton tube prevented the collapse of the stool. Figure 8 shows these components, which are namelya last carton the two tube covers, prevented the cylinder the collapse and the of tube the stool., together Figure with8 shows the assembled these components, device. which are namely the two covers, the cylinder and the tube, together with the assembled device. namelyThe the resistance two covers, tests the show cylinder that andan 80 the kg tube, person together can safely with thesit assembledand swing device.on the stool without The resistance tests show that an 80 kg person can safely sit and swing on the stool without failureThe for resistance more than tests 500 show sitting that movements. an 80 kg person can safely sit and swing on the stool without failure failure for more than 500 sitting movements. for more than 500 sitting movements.

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Figure 8. Carton stool, components and final device. Figure 8. Carton stool, components and ﬁnal device.

4. Conclusions and Future Research 4. Conclusions and Future Research Recently, the importance of packaging management and its increasing functions has become Recently, the importance of packaging management and its increasing functions has become relevant due to innovations and new expectations in packaging materials and methods. According relevant due to innovations and new expectations in packaging materials and methods. According to to the multifunctional packaging concept, logistics, marketing and sustainability are the fundamental the multifunctional packaging concept, logistics, marketing and sustainability are the fundamental roles that packaging should consider and integrate. At the same time, the environmental impact of roles that packaging should consider and integrate. At the same time, the environmental impact of packaging material and waste has risen due to the quantities and quality of such discharged packaging material and waste has risen due to the quantities and quality of such discharged materials. materials. The reuse and recycle of packaging in the supply chain is fundamental, especially in certain The reuse and recycle of packaging in the supply chain is fundamental, especially in certain supply supply chains, such as the humanitarian context. chains, such as the humanitarian context. The presented research proposes multiple methods to optimize the treatment of the end-of-life The presented research proposes multiple methods to optimize the treatment of the end-of-life of of packaging after their use in emergency fields and after they have fulfilled their primary packaging after their use in emergency fields and after they have fulfilled their primary transportation transportation and stocking function. In collaboration with the United Nations Humanitarian and stocking function. In collaboration with the United Nations Humanitarian Response Depots-Lab Response Depots-Lab (UNHRD-Lab), we designed and tested several basic equipment for everyday (UNHRD-Lab), we designed and tested several basic equipment for everyday life, including a backpack, life, including a backpack, cradle, slippers and stool, to aid people affected by disasters and cradle, slippers and stool, to aid people affected by disasters and simultaneously reduce the generation simultaneously reduce the generation of packaging waste. The effectiveness of such devices was of packaging waste. The effectiveness of such devices was tested through basic measures of resistance, tested through basic measures of resistance, obtaining promising preliminary results encouraging obtaining promising preliminary results encouraging future actions. future actions. This study serves as a starting point for future research on the continuous optimization of This study serves as a starting point for future research on the continuous optimization of approaches and methodologies for the reuse of packages in new and different applications in approaches and methodologies for the reuse of packages in new and different applications in humanitarian supply chains. It could be interesting to test the developed objects in a refugee camp humanitarian supply chains. It could be interesting to test the developed objects in a refugee camp to to understand their weaknesses and to attempt to improve them. As the experimental evidence is understand their weaknesses and to attempt to improve them. As the experimental evidence is encouraging, in the near future, several of these prototypes will be sent into the field for testing, with encouraging, in the near future, several of these prototypes will be sent into the field for testing, with collection of technical and social results. collection of technical and social results. Author Contributions: M.B. and F.P. revised the background and provided the methodology to be adopted; AuthorA.R. collected Contributions: the input M materials;.B. and F M.G..P. revise andd F.P. the conceived background the prototypes;and provide M.B.d the and methodology F.P. performed to be the adopt lab-tested; Acollecting.R. collected the results;the input A.R., materials; M.B. and M. F.P.G. and wrote F.P the. conceived paper. the prototypes; M.B. and F.P. performed the lab-test collectingAcknowledgments: the results;The A.R Authors., M.B. and express F.P. wrote a deep the sense paper. of gratitude to the United Nations Humanitarian Response Depots-Lab (UNHRD-Lab), Brindisi, Italy for its support and valuable information provided during this study. Acknowledgments: The Authors express a deep sense of gratitude to the United Nations Humanitarian ResponseConflicts ofDep Interest:ots-LabThe (UNHRD authors-Lab), declare Brindisi no conflict, Italy for of interest. its support and valuable information provided during this study. References Conflicts of Interest: The authors declare no conflict of interest. 1. Domnica, D. Review Concerning the Functions of Packaging. Land Forces Acad. Rev. 2010, 1, 44–49.

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