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U.S. Army Combat Capabilities Development Command 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 paper. Food use makes up ~ 50% of all packaging. Usually packaging materials go to a landfill. Recycling (issues of contaminants); biodegradable packaging; incineration. Packaging industry is one of the largest U.S. industries UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 2 2 1 5/29/2020 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 Packaging Waste: 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 2 5/29/2020 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 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 6 6 3 5/29/2020 UNCLASSIFIED//FORWASTE OFFICIAL USE ONLY//STORAGEDRAFT//PRE-DECISIONAL Solid waste in the form 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 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL PROJECT APPLICATIONS FOR THE MILITARY UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 8 8 4 5/29/2020 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 bioplastics Formulation Polymer is compounded into pellets UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 9 9 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL RENEWABLE /BIOBASED FOOD PACKAGING 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 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 10 10 5 5/29/2020 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 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 11 11 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 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 12 12 6 5/29/2020 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL TYPES OF CONTAINERS Primary - comes into direct contact with food (e.g., pouch, can or jar). Secondary - an outer box, case or wrapper that holds & protects primary containers. Tertiary - group several secondary cartons together into pallet loads or shipping units. UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 13 13 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL CURRENT SYSTEM CONCERNS Primary Packaging Secondary Packaging Tertiary (Unit Load) Foil laminate can only be Tight Packing Arrangement Pallet overhang sterilized by retort Excessive bulge Exposed containers MRE size variation / bulky Container 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 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 14 14 7 5/29/2020 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL POLYMERS FOR FOOD PACKAGING UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 15 15 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 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). UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 16 16 8 5/29/2020 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL POLYMERS Most important ones used: – Cellulose acetate (type of cellophane) – Ethylene co-vinyl alcohol – Polyvinyl alcohol (water soluble, great oxygen barrier) – Polyamide (Nylon) – Polyesters (PET & Mylar) – Polyethylene/Polypropylene (very good water vapor barrier) – Polyvinylidene chloride (Saran) – Polyvinyl chloride (PVC) – Polyhydroxyalkanoates (PHA) (biodegradable decent barrier for oxygen) UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 17 17 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL MEAL, 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/starch, crackers, spread, dessert/snack, beverage, accessory packet, plastic spoon and Flameless Ration Heater (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/bag, 21.8 lbs (9.9 kg)/case o 12 bags per case o “A” and “B” cases (12 different menus each) UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 18 18 9 5/29/2020 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 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 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 19 19 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL PACKAGING STRUCTURES MRE Meal Bag •Aluminum foil has LDPE/LLDPE excellent oxygen and water vapor MRE Retort Pouch Structure barrier properties Polyolefin Inner Layer and is considered to Aluminum Foil be a zero barrier Polyamide Outer Layer Polyester •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 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 20 20 10 5/29/2020 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL MILITARY REQUIREMENTS Shelf Life 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 – Pallets: High altitude parachute drop UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 21 21 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL CURRENT RATION PACKAGING Current Technology MRE Retort Pouch Structure MRE Non-retort Pouch Structure UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL 22 22 11 5/29/2020 UNCLASSIFIED//FOR OFFICIAL USE ONLY//DRAFT//PRE-DECISIONAL PRIMARY PACKAGING FOIL PACKAGING Aluminum foil - Primary Packaging – Excellent barrier to oxygen and water vapor – Often laminated
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