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5/29/2020

UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL

U.S. ARMY COMBAT CAPABILITIES DEVELOPMENT COMMAND

Sustainable Packaging

Dr. Jo Ann Ratto Materials Engineer US Army Combat Capabilities Development Command Soldier Center

DISTRIBUTION STATEMENT B. Distribution authorized to U.S. Government agencies only. Other requests for this document shall be referred to US Army Combat Capabilities Development Command Soldier Center, ATTN: FCDD-SCP-MO (David Ziegler) 10 General Green Avenue, Natick, MA 01760

15 Apr 2020 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 1

UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL PACKAGING ENVIRONMENTAL ISSUES

Packaging of all forms makes ~ 33% of the disposable solid waste in U.S. most is . use makes up ~ 50% of all packaging. Usually packaging materials go to a landfill. (issues of contaminants); biodegradable packaging; incineration. Packaging industry is one of the largest U.S. industries

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL CURRENT ENVIRONMENTAL CONCERNS

United States Military - Army

Average Solid Waste: 7lbs/soldier/day

Total Plastics Waste: 30,000 Tons/Year

Total : 14,000 Tons/Year Long-term health effects observed in Soldiers that are subjected to smoke and toxins from solid waste burnUNCLASSIFIED//FOR pits OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 3 3

UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL U.S. NAVY WASTE PROBLEMS

Waste Management Approach and Policy • MARPOL Annex V and U.S. Public Law 100-220, Act to Prevent Pollution from Ships • OPNAVINST 5090.1C Environmental Readiness Program Manual

Concerns associated with solid waste on board naval vessels include: storage space, health concerns, and labor UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 4 4

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL USS NIMITZ SOLID WASTE STUDY

Data represents a 24-hour period on the USS Nimitz in 2008 (4316 People) UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 5 5

UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL NAVSEA PLASTICS WASTE PROCESSORS

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Solid waste in the of thermally pressed disks are stored on ship until proper disposal can be conducted. They contain microorganisms that grow on food waste and create odors and potential health problems.Bacteria Fungi

Puck generated from contaminated plastic waste on UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 7 board ship 7

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PROJECT APPLICATIONS FOR THE MILITARY

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL How Biodegradable Plastics Are Made

Biodegradable Biobased Biodegradable polymers in Starting with corn natural soil and water environments, home and industrial composting facilities Corn Sugar One of many products made from each kernel of corn, used as feedstock for biodegradable polymers.

Applications Polymer can be processed on Fermentation conventional equipment A patented process, and used transforms the sugar in everyday products into

Formulation Polymer is compounded into pellets

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL RENEWABLE /BIOBASED LIFECYCLE CONCEPT

Bio-Based Renewable Feedstock Compost Bio-Based / Biodegradable Polymers & Additives

Coextrusion

Multilayerd films that are: • Biodegradable • Down-gauged • Foil-free • High barrier • Tough & strong

Ration Packaging

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL FOOD PACKAGING

General requirements: – Nontoxic – Keep the food safe – Prevent contamination from microorganisms – Barrier to moisture, oxygen, UV light & odors – Provide resistance to physical damage during rough handling

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL FOOD PACKAGING

– Be tamper-resistant or tamper-evident – Easy to open – Have dispensing & resealing features – Be disposed of easily – Meet size, shape & weight requirements – Have attractive appearance – Printability features – Low cost – Be compatible with food

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL TYPES OF

Primary - comes into direct contact with food (e.g., pouch, can or ). Secondary - an outer , or wrapper that holds & protects primary containers. Tertiary - group several secondary together into loads or shipping units.

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL CURRENT SYSTEM CONCERNS

Primary Packaging Secondary Packaging Tertiary ()

Foil laminate can only be Tight Packing Arrangement Pallet overhang sterilized by retort Excessive bulge Exposed containers MRE size variation / bulky failure Excessive Weight Excessive weight Limited stacking strength Sealing Issues Processing limitations Unstable unit loads Excessive Gaps Subject to field-stripping Poor Utilization of Trailers High Waste Generation

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POLYMERS FOR FOOD PACKAGING

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POLYMERS FOR FOOD PACKAGING

Polymers of >100,000 molecular weight Crystalline Thermoplastic polymers can be melted and reformed repeatedly. Limited number of polymers are used in food packaging; however, these are combined in various ways to produce common packaging materials (e.g., copolymers and processing methods).

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL POLYMERS

Most important ones used: – acetate (type of ) – Ethylene co-vinyl alcohol – Polyvinyl alcohol (water soluble, great oxygen barrier) – () – (PET & Mylar) – / (very good water vapor barrier) – Polyvinylidene chloride (Saran) – Polyvinyl chloride (PVC) – Polyhydroxyalkanoates (PHA) (biodegradable decent barrier for oxygen)

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL , READY TO EAT (MRE)

The MRE is the cornerstone of individual rations and is used by all the Services, providing the Office of the Surgeon General’s approved nutritional requirements for a military ration for up to 21 days.

• 3 MREs per day equal a day’s worth of subsistence

• Menu Variety: 24 Menus (4 vegetarian), each with entrée/, crackers, spread, dessert/snack, beverage, accessory , plastic spoon and (FRH)

• Shelf stable for 3 yrs at 80°F (27°C) & 6 months at 100°F (38°C)

• Nutritional Data: averages 1250-1300 calories per meal (13% protein, 34% fat, 53% carbohydrate)

• Weight: 1.5 lbs (0.68 kg/, 21.8 lbs (9.9 kg)/case o 12 per case o “A” and “B” cases (12 different menus each) UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 18 18

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MILITARY SPECIFICATIONS AND PERFORMANCE

Microbial Validation Long Term Storage Study Water Content Sensory Testing Lipid Oxidation Recycling Burst / Seal Strength Insect Infestation Water Activity Distribution Study Oxygen Concentration Transportation Study Drop and Vibration Testing Field Study

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL PACKAGING STRUCTURES

MRE Meal Bag •Aluminum foil has LDPE/LLDPE excellent oxygen and water vapor MRE Structure barrier properties Polyolefin Inner Layer and is considered to Aluminum Foil be a zero barrier Polyamide Outer Layer •However stress MRE Non-Retort Pouch cracking and pin and Over wrap holes significantly Structure decrease barrier PE or Ionomer Inner Layer properties Aluminum Foil Outer Layer Polyester

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MILITARY REQUIREMENTS Requirements – MRE 3 yrs at 80°F; 6 mos at 100°F

Barrier Requirements – Oxygen Transmission Rate: 0.06 cc/m2/day – Water Vapor Transmission Rate: 0.01 g/m2/day

Protection from – Microbial contamination – Insect and rodent penetration and infestation

Abuse Levels – Cases: Low altitude freefall airdrop – : High altitude parachute drop

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL CURRENT RATION PACKAGING

Current Technology

MRE Retort Pouch Structure MRE Non-retort Pouch Structure

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PRIMARY PACKAGING FOIL PACKAGING Aluminum foil - Primary Packaging – Excellent barrier to oxygen and water vapor – Often laminated to paper or plastic films for strength and performance – Aluminum is a relatively expensive metal; recycling is common. – Foil is often coated with to avoid undesirable color & flavor reactions depending on the specific food.

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL Why the need for non-foil packaging? Improved Performance – Eliminate pinholes and stress induced cracking Simplified Manufacturing – Reduce the number of steps – Deeper draw during pouch forming processes Broaden Food Processing Techniques – Microwave – Radio Frequency – High Pressure Pasteurization Reduced Waste – Recyclable packaging – Biodegradable packaging

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL ALTERNATIVES FOR HIGH BARRIER POLYMERS

Nanocomposites

High Barrier

High Barrier Multilayered Structures

Other Additives

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL LAMINATES / CO-EXTRUSION

Multilayers of different materials used to obtain the best desired packaging features; for example, the heat sealability of plastics, the barrier properties of aluminum foils & the strength of polymer or paper layers. Some laminates contain up to 8-12 layers to package a particular product.

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL Polyhydroxyalkanoates (PHA) Biodegradable Polymers

O O R O + HO OH HO OH

Bacteria Microbially Catalyzed Catalyzed O Polymerization Depolymerization x n

O O PHA O O n m Tm = 150°C

Polyhydroxy buterate valerate (PHBV) Versatile range of structures: homopolymers, copolymers, terpolymers, block-copolymers

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL PVOH MATERIAL

[CH CH ] 2 n OH Polyvinyl Alcohol (PVOH)

POVAL CP-1220T10 (Kuraray W-60 (Stanelco) America) • 96% Hydrolyzed • 73% Hydrolyzed • More Difficult Melt Processing • Contains 20% Ethylene • Higher Strength Glycol • More Water Resistant • Contains 10% Talc • Higher Solvent Resistance • Easier Melt Processing

• More Flexible UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 28 28

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL MATERIAL SELECTION BY RHEOLOGY

PHA Polymers PVOH Polymers

Polymers run on capillary rheometer at three different melt

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL MATERIAL SELECTION BY RHEOLOGY

10000.00

1000.00

100.00

10.00 ApparentViscosity (Pa-S)

1.00 10 100 1000 10000 Apparent Shear Rate (1/sec)

PHA P2001 @185°C POVAL PVOH @ 190°C

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL OXYGEN BARRIER PROPERTIES

2500 0% RH 2000 60% RH 2000 90% RH

1500

999 1000

500 250 211 238

60 27 41 52 Oxygen Transmission Rate (cc/m2-day)TransmissionRateOxygen 0 PVOH PHA PVOH/PHA

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL PROTOTYPE READY TO EAT (MRE) MENU BAGS

Meal Ready-to-Eate (MRE) menu bag (top) and prototype LLDPE-soy bags containing soy at 0%, 5%, 10%, 15% and 20% by weight (left to right)

* Menu bag contains brown pigment not included in prototype

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL NATICK EIGHT-LAYER CO-EX FILMS PRODUCED WITH SOY FLOUR

• 20% soy blend with 3% compatibilizer added to layers to increase total soy flour loading (20% MB) • Eight-layer films produced with 0 , 5, 10, 15, and 20% soy flour in Braskem LL318 LLDPE (20% MB added as a layer) • Soy materials added to increase levels of bio- based materials in films

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL MULTILAYER CO-EXTRUSION PROCESS SAMPLE DESIGN

5% Total Soy Content 10% Total Soy Content

15% Total Soy Content 20% Total Soy Content Denotes Layer with 20% Soy UNCLASSIFIED//FOR OFFICIAL USE MasterONLY//DRAFT//PRE-DECISIONAL-Batch 34 34

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL FILM CROSS SECTIONAL ANALYSIS

0% 5% 10% Soy Soy Soy

15% 20%

SoyUNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONALSoy 35 35

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SECONDARY PACKAGING CORRUGATED PRODUCTS FOR MRE CONTAINGE In primary containers, most paper products are treated, coated or laminated. Paper source is and reprocessed waste paper (unless sanitary virgin pulp specified). – Paper often bleached, coated or impregnated with waxes, , lacquers, plastics or of aluminum foil. – Additives used to increase flexibility, tear resistance, , grease resistance, printability, sealability, barrier properties,

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WHY SECSECONDARY PACKAGING LIGHTWEIGHT, CORRUGATED MRE SHIPPING CASE

• Need to work on new MRE case originated from enormous amounts of packaging waste in the field

Facts MRE Fiberboard Waste/Pallet 190 lbs Average Annual Production 3,300,000 cases (68,750 pallets) Total Fiberboard Annual Waste 6,531 tons

Removal Cost at $50/Ton $294,250

• Alternative cases for MREs were evaluated under SERDP research and development and then moved to ESTCP demonstration/validation programs • Technical efforts have been documented in technical reports and publications.

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL PERFORMANCE OBJECTIVES

Data Requirements Result Performance Objective Metrics Success Criteria s Quantitative Performance Objectives Reduce amount of solid Disposal data for solid Greater than 20% FAIL Tons/day of solid, non- waste generated from waste overall weight reduction (15% hazardous ration reduced waste secondary packaging of secondary packaging vs sent to landfill 20%) Compression data Maintain compression PASS Maintain compression Maintain functioning from finished strength to support 4 strength of MRE fiberboard compression strength (lbf) of containers after unit loads (3950 lbs) containers containers within representative environmental testing during long term environments storage Ensure repulpability to meet Fibre Box voluntary No more than 15% fiber PASS operating Percent fiber-on-fiber yield standard for reject standards during recycling repulpability Ensure recyclability to meet Percent reject of recycled fiber Fibre Box voluntary No more than 10 PASS recycling mill operations standard for percent decrease in recyclability fiber strength properties Ensure emissions from Identified emission gases from U.S. EPA emissions Zero identified toxic PASS burning of containers laboratory burn tests protocol emissions as a result of contain no toxic chemicals burn testing Ensure fiberboard can Convert fiberboard in waste-to- U.S. EPA emission Create pellets from undergo waste-to-energy energy converter and measure guidelines waste-to-energy trail trials BTUs Ensure biodegradability and Percent mineralization of ASTM D6868 Meet the requirements PASS compostability of fiberboard chemical carbon in compost/soil specification on of ASTM D6868 biodegradable paper specification coatings Maintain resistance to insect Percentage of insect penetrations Inspection of Less than 20% PASS infestation per 30 containers containers after insect penetration failure exposure Ensure MRE can withstand Percentage of failures due to Percentage of defects Less than 12% failure PASS aerial delivery bursting of puncture on dropped MREs rate Ensure MRE can withstand Percentage of packaging defects Inspection of MREs Less than 10% failure PASS distribution / transportation after distribution and rate study transport cycle Qualitative Performance Objectives Soldier acceptance of Field test questionnaire Survey evaluation Positive feedback that PASS container from individual soldiers could use this soldiers container Ensure manufacturability of Observation / inspection of Manufacturing Complies with industry PASS corrugated ration container converted material specifications ASTM standards set by Fibre D4727 & D5118 Board Association Ensure ease of packing Observations during the Feedback and End item inspection at PASS during assembly process pf assembly and packing processes inspection from the copackers with the MRE rations converter on the certificate of packaging of MRE conformance and UNCLASSIFIED//FOR OFFICIAL USE ONLY//rationsDRAFT //PRE-DECISIONAL production report 38 38 38

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TEST DESIGN

Demonstration/Validation Tests Reduction of Solid Waste Environmental testing – ISTA and ASTM testing • Compression testing • Cobb Testing Repulpability/recycling analysis Emission testing Waste to Energy conversion / Compostability Insect Infestation Airdrop trials Unit load transportation Field Study Manufacturability Assembly

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LIGHTWEIGHT, CORRUGATED MRE SHIPPING CASE

Current Case - Solid Fiberboard New Case - External 90# Wet Liner Strength Medium Liner 69# Inner Ply Internal Liner Laminate Structure Solid Corrugated

Liner Grade 90 # Paper 69# liner 30# Wax Alternative medium C flute

Container Design Regular Slotted Container (RSC) with Insert UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 40 40

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KEY POINTS

Transport • Improve cube utilization of trailer loads by adding 1 pallet load to trailer shipments • Decrease weight by 21 lbs per unit load

Disposal • Eliminating 17 percent of packaging waste • Create new alternatives for recycling of fiberboard materials • Reduce backhaul operations from contingency basing locations

Other Potential Applications • Meal, Cold Weather and First Strike Ration • Other packaging containers for all military services

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KEY POINTS

Sourcing Location # Corrugators • Competitive purchase with corrugators Evansville, Indiana 9 nationwide who can fabricate the case • Simplify sourcing with corrugator Cincinnati, Ohio 17 companies Mullins, South Carolina 9

Manufacturing • Can produce this fiberboard at corrugators located near assemblers

Packaging • Reduce packaging related waste • Reduce weight of unit load • Add recyclability and repulpability

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL Tertiary Packaging Alternative for Ration Cases and Pallet Loads Bio-based, paper-based, biodegradable and/or reduction of material for straps (conventional recyclable plastics with additive to decrease density)

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TERTIARY PACKAGING

Paper-based Straps

Pallet Load of Meal, Ready-to-Eat™

Example of Corrugated Pallet Construction

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Alternative Strapping

Derived from renewable resources May apply to individual ration cases and/or unit loads Materials explored: ─ Polylactic acid (PLA) and modified PLA polymers ─ Polyhydroxyalkanoate (PHA) copolymers ─ Polyhydroxybutyric acid (PHB) copolymer blends ─ Blends of PHA and PLA ─ Polybutylene succinate adipate (PBSA) ─ Paper

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Key Metrics for Case Straps

Capability Baseline Threshold Objective Current Break Strength Current 150 lbs 200 to 220 (Bio-based) 100% Polypropylene lbs 243 lbs for 95% PLA- Ameriqual (white): 220 lbs based commercial SoPakCo (black): 210 lbs Japanese strap Wornick (yellow): 150 lbs

Cost Current 5% cost 10% cost $0.0005 reduction reduction for 2 straps per case

Bio-based Current 20-50% 90-100% content 0% Strap samples with an anticipated 85%-99% bio-based content can be fabricated

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Commercial Bio-Based Straps

Straps Made with 95% PLA Break Strength: 243 pounds

By Sekisui Jushi Corporation, Japan http://www.sekisuijushi.co.jp/jg/sg/bandcore.html UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 47 47

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Biodegradability of Plastics

Figure 3: Biodegradation Rates in Compost PHA Film by Metabolix

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Paper-Based Straps • Commercial product • Recyclable along with corrugate, , and mixed paper in the majority of established municipal recycling programs Patent No.: US 7,118,648 • Adaptable stretch • High strength - up to 450 lbs • Can work with many types of existing strapping equipment • “Soft savings” through elimination of plastic strapping recycling equipment and plastic sorting labor stream

Industrial Paper Straps and Strapping Equipment by SDF Strapping, Inc.

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL PROJECT APPLICATIONS FOR FILM

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL Mulch Films

100% Biodegradable Mulch Film provides growers with all of the performance characteristics of conventional polyethylene (PE) mulch films. Reduced weed problems Increased plant growth rate Enhanced moisture control Good stretch properties Increased soil temperature Easy to perforate Extension of growing season Easy to lay using existing equipment

At the end of the growing cycle, simply plow Organix A.G. Film™ into the soil. Temperature, humidity, and micro-organisms in the soil will turn Organix A.G. Film™ into , water and CO2 leaving no harmful residue.

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL Mulch Films

Eliminating waste to landfill with sustainable, beneficial solutions and technologies is our core competency.

Organix A.G. Film™ has been proven in the field to provide growers with all the performance characteristics of conventional PE mulch film and can be down gauged in thickness for additional cost savings.

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL Polylactic Acid (PLA)

Structure of PLA PLA in Film and Fiber • Ease of Processability • Biodegradable via Municipal Composting • Applications include fiber bedding, carpet fiber, flexible UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 53 and rigid packaging 53

UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL WASTE MATERIALS

Waste Stream

Solae Soy Fiber

GP Pro 5

Arsoy

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL BIODEGRADATION TESTING AATCC Test Method 30-2004 Antifungal Activity, Assessment on Textile Materials: Mildew and Rot Resistance of Textile Materials (Soil Burial)

ASTM 6691 for specification ASTM 7081 • Columbus Instruments Micro-Oxymax system • 80 vessels • Carbon dioxide and methane sensors • Capability to do ASTM aerobic and anaerobic testing for soil, compost or marine environment. • Visual basic program developed for rapid data analysis

Respirometer system for measuring biodegradation in marine environmentUNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 55 55

UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL PHA VS. (TIER I)

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UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL ACKNOWLEDGEMENTS

. Robina Hogan U.S. Army Combat Capabilities Development Command Soldier Center

Strategic Environmental Research Development Program and Environmental Security Technology Certification Program U.S. Soy Board

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