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Popcorn Shed // Amcor Doubles the Shelf-Life Of // Amcor’s Case Study // Popcorn Shed POPCORN SHED // AMCOR DOUBLES THE SHELF-LIFE OF POPCORN SHED’S *58% Carbon Recyclable PREMIUM POPCORN footprint reduction WITH A RECYCLABLE SOLUTION Easy opening 2x longer shelf life CONSUMERS EXPECT CONVENIENCE Popcorn is far more susceptible to moisture and oxygen than most other snacking foods. In as little as a few hours after opening a pack there is a noticeable loss of freshness as the product loses its crunch and becomes soggy. This is why Popcorn Shed houses its popcorn within plastic pouches that sit inside ‘sheds’ of cardboard packaging. Popcorn Shed had previously been protecting its popcorn with a laminated barrier film. This PET AlOx / LDPE clear packaging is mainly used for Popcorn Shed founders Sam Feller and Laura Jackson ready meals and frozen food due to its reliable and strong barrier properties. However, the material THE POPCORN SHED GROWTH STORY wasn’t conducive to easy-opening, which resulted Popcorn Shed is an independent London-based in Popcorn Shed receiving several customer premium popcorn maker that prides itself on complaints. great tasting products, high-quality ingredients, beautiful packaging and excellent customer As Sam explains: “We were receiving lots of service. The company, which began with cousins complaints that customers couldn’t open the bags Sam Feller and Laura Jackson making popcorn without a pair of scissors, or it spilled on opening. in their garden shed, has enjoyed rapid growth So, while it provided a good barrier, it didn’t quite since launching in 2016. have the properties we needed to meet our customers’ expectations of a luxury brand.” The company was the first to put popcorn in an outer carton (using bag-in-box), which makes the Additionally, its previous PET structure meant product highly shareable and perfect for gifting that the liner bag was non-recyclable. While purposes. Its packaging and the high quality of PET bottles are recyclable, there is currently no ingredients used in its popcorn is instrumental in recycling stream for PET-based bags and pouches. setting the brand apart in a busy market. The new AmLite pouch is mono-OPP/PP which means that it fits recycling streams available in For more information: several European countries. With sustainability https://popcornshed.com/ becoming a growing issue for consumers this increased recyclability ultimately helps them too. Page 1 // www.amcor.com // Amcor’s Case Study // Popcorn Shed THE SUSTAINABLE SOLUTION ABOUT AMLITE STANDARD RECYCLABLE Popcorn Shed required a packaging material The AmLite Standard Recyclable line of high that would keep its premium popcorn fresh, barrier packaging is a unique line of metal-free was easy for consumers to open, and easy for packaging that is recyclable where these streams Amcor has a dedicatedAmcor sustainability has a dedicated team sustainability team them to recycle in someFor more European information,For please more countries. contactinformation, please contact [email protected]@Amcor.com exist. By utilizing Amcor’s significant experience Amcor’s AmLite Standard Recyclable packaging in barrier coating and conversion, AmLite ensures delivered on all three requirements. The a lightweight material that offers excellent Amcor has a dedicated sustainability team packaging can be recycled in front-of-store For more information, please contact product protection, that is easy to open, and can crisp packet recycling systems and is suitable [email protected] be customised with a highly visible design. for polypropylene recycling where the facilities exist (i.e. Germany). ABOUTAssessment POPCORNAssessment SHED Report Report(Fact sheet) (Fact sheet) PopcornEnvironmental Shed is Environmentalthe life cycleUK’s assessment first life premiumcycle of assessment packaging gourmet of packagingThe packaging offers the same high-barrier popcornPrepared brand, for: whilePrepared Popcorn competitors for: Popcorn apply spray- properties as conventional metallised orientated on and powder coatings in an industrial process,Assessment polypropylene Report (OPP). (Fact However, sheet) being metal- PopcornProposed Shed usesPackaging:Proposed an artisan Packaging:OPP30/pri/prt/adh/OPP cooking OPP30/pri/prt/adh/OPPprocessEnvironmental lifefree, AmLite cycle it has assessment the18 AmLite benefit of packaging 18of transparency, which with each production run. enables consumers to see the product inside Prepared for: Popcorn >> Overall comparison>> Overall of comparison product performance of product performancethe packaging, a requirement for Popcorn Shed. OperatingEvolution out of the of product Evolutiona garden of the shed product since 2016,Proposed Packaging: OPP30/pri/prt/adh/OPP AmLite 18 Popcornenvironmental Shed is indicators: aenvironmental home-grown, indicators: family-owned-17 % -17 %The-22 combination % -22 of %an OPP-28 structure % -28 and % business and a Made in Britain artisanal brand. AmLite’s metal-free barrier has an impact on >> Overall comparison of product performance They are also the first UK popcorn brand to be the recyclability of packaging. Metallisation Evolution of the product packaged in ‘shed’ cartons, each with its ownenvironmental indicators:can interfere with Infra-Red-17 % material detection-22 % -28 % personality andRelative theme. Relative systems at recycling sites, but AmLite Standard impact (%) impact (%) Recyclable can be easily detected and machine For more information: sorted for recycling. www.popcornshed.com Relative impactAdditionally, (%) the move to AmLite Standard Recyclable from the previous laminate has provided substantial reductions in carbon footprint, water consumption and non- renewable primary energy demand. The new packaging’s carbon footprint is 58%1 lower, meaning that this solution is much more Non-renewable primaryNon-renewable primaryCarbon footprint Carbon footprintWater consumptionWater consumption energy demand energy demandsustainable(fossil) than (fossil)the previous packaging. Non-renewable primary Carbon footprint Water consumption energy demand (fossil) Number of CFL lightNumber bulbs of CFLNumber light63 thebulbs of carsnumber Numberdriven of for of 1 cars drivenNumber for of1 10 minuteNumber7010 the of 10 number minute burning for 1 yearburning for 1 yearcars drivenyear for year showers of showers10 minute 1 year saved showers saved Savings (1M m²)Savings (1M m²)809 809 22 22 3450 3450 Note: Figures may be skewedNote: Figures as a consequence may be skewed of rounding. as a consequence Results are of given rounding. for 1 millionResults m²are. given for 1 million m². 2030Number the of numberCFL light bulbsof CFL Number of cars driven for 1 Number of 10 minute burning for 1 year year showers Baseline packaging Baseline12PETAlOx/Pri/prt/adh/PE40 packaging 12PETAlOx/Pri/prt/adh/PE40 light bulbs burning for 1 year saved Author AuthorRémy Teuscher Rémy Teuscher e-mail [email protected] (1M m²) [email protected] 22 3450 Accuracy AccuracyMeets standard requirementsMeets standard requirementsDate of approval Date13.09.2019 of approvalNote: Figures13.09.2019 may be skewed as a consequence of rounding. Results are given for 1 million m². Scope ScopeCradle-to-grave Cradle-to-grave Validity period Validity1 year period 1 year Baseline packaging 12PETAlOx/Pri/prt/adh/PE40 Author Rémy Teuscher e-mail [email protected] Accuracy Meets standard requirements Date of approval 13.09.2019 Page 2 // www.amcor.com << Analysis n°9949 >><< Analysis n°9949Confidential >> informationConfidential - Not for informationPublication - Not for Publication Page 1 Page 1 Scope Cradle-to-grave Validity period 1 year << Analysis n°9949 >> Confidential information - Not for Publication Page 1 // Amcor’s Case Study // Popcorn Shed FROM GARDEN SHED TO WORLDWIDE DISTRIBUTION, THANKS TO EXTENDED SHELF-LIFE Thanks to its high performing barrier, Amcor’s AmLite Standard Recyclable packaging has doubled the shelf-life of Popcorn Shed’s premium popcorn. This has had a significant impact on the brand’s export and ecommerce opportunities, with global export now accounting for 25% of the brand’s turnover. As Sam explains: “Since we implemented Amcor’s packaging our shelf-life into trade has gone from six months to 12 months, which is hugely important for the export market. When we’re sending products to Japan and Australia customers demand a 12-month minimum shelf-life as the products sit on a boat for three months before they reach the destination. “Other producers will gas flush the popcorn to keep food fresh for longer and achieve that shelf- life, but we don’t need to do that. Now, Amcor’s packaging ensures that popcorn that has been in the bag for 12 months is still as fresh as the day it was first made. We’re delighted with the results and will continue to use the bags moving forwards.” Popcorn Shed’s packs are now simple to open, guarantee a fresh taste, and consumers are able to see the product inside the pack. Amcor’s solution also enables Popcorn Shed to print its brand on the bag, which further improves the appeal of the packaging. As Sam adds: “Amcor’s AmLite Standard Recyclable* is a fantastic product for our application. It opens like a crisp packet, so it is very easy to use as a consumer, and its barrier properties are excellent.” These elements have helped Popcorn Shed position itself as a high-quality, premium gifting product to consumers all over the world. *This claim is a general guidance and does not mean the packaging can be recycled currently everywhere
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