Target EPS removal goal
 Goal: EPS removal from Target packaging by 2025
o This does not have to be all at once. Vendors can remove EPS from individual items or EPS
components as a work in progress.
o Solution does not have to be consistent across vendor or category.
 Pricing/cost notes:
o Target is aware that many solutions will increase cost.
o Target sees this as a partnership and opportunity and wants to have costing discussions
continually through concept, design, testing, and implementation phases of EPS removal.
 Exceptions:
o Currently there are no plans to grant exceptions to EPS removal.
 What’s in this document
o Acceptable Solutions
o Methods & strategies to achieve EPS removal.
o These may be between vendors of similar product types or may be used for idea
generation.
Methods & strategies to achieve EPS
 Acceptable solutions
removal.
o EPE (Expandable Polyethylene): polyethylene foam plastic, commonly known as pearl cotton.
o
o
o
o
o
Features: small density, good flexibility, high recovery rate; shock resistance better than
polystyrene plastic; independent bubble structure, low surface water absorption; good
penetration resistance; acid, alkali, salt, oil and other organic solvents , Excellent aging
resistance; no flowing at high temperature, no brittleness at low temperature.
Construction: EPE can be extruded or foamed, can be made into sheet or pipe, and then
punched, cut, bonded and formed. It has good toughness, is not easy to break, and has
good cushioning performance.
o Sheets can be glued together to make more complex shapes in place of molds
Recyclability: A certain amount of EPE recycled material (70%) is allowed to be mixed in
manufacturing, so it is better for the environment
Costing: In low quantities EPE is more cost effective than molded EPS but at high
quantities this relation is reversed.
Availability:
o In China: Molded EPE is not a viable solution for China based vendors as molded
EPE suppliers are very rare in China.
o EPE wrap, sheets, blocks, and corners are available in China.
Methods & strategies to achieve EPS
 Acceptable solutions
removal.
o
Paper Honeycomb
o Features: High strength to weight ratio. Uniform crushing strength under compression.
Manufacturing at low cubic input to high volume output
o Construction: a series of hexagonal shaped cells, nested together creating a sheet when
expanded with approximately 95% open space. Typically available as 1. Continuous
unexpanded honeycomb core (large volume users) 2. Unexpanded slices (fixed sizes
shipped knock down) 3. Pre-expanded sheets (for specific orders, fits, and uses)
o Recyclability: same as any paper based packaging, biodegradable & compostable
depending on ink/glue use
o
Paper Cushioning
o Features: High strength to weight ratio. Uniform crushing strength under compression. Can
be made using scrap material from production. Sourcing available from existing shipping
box supplier. Highly flexible and adaptable solutions achievable
o Construction: Typical paper cushioning is done with paperboard or corrugate pieces,
construction is consistent with how these materials are otherwise produced.
o Recyclability: same as any paper based packaging, biodegradable & compostable
depending on ink/glue use
Methods & strategies to achieve EPS
removal.
 Acceptable solutions
o
o
Molded fiber: Made from waste paper and/or natural fibers and pressed into molded shapes for
protection and housing of products.
Construction:
• Type-1 Molded Fiber Products – Thick Wall
• Manufactured using a single mold with product wall thickness from about 3/16 to 3/8 inches (5mm to
10mm). One surface is relatively smooth, with one side rough. Primarily used for support packaging of nonfragile, heavier items. (vehicle parts; furniture, motors etc.). As well as, plant, floral and nursery pots and
containers. Oven dried.
• Type-2 Molded Fiber Products – Transfer Molded
• Manufactured using one forming mold and one transfer mold with product wall thickness from about 1/8 to
3/16 inches (3mm to 5mm). Surfaces are relatively smooth on one side. Most common use is for egg
cartons and trays. New designs are used for many types of electronic product packaging such as cell
phones, DVD players etc. Also, used for hospital disposables, electrical appliances, office equipment,
tableware and fruit and drink trays. Oven dried.
• Type-3 Molded Fiber Products – Thermoformed (Sometimes called “thin-wall”)
• Manufactured using multiple heated molds with product wall thickness of about 3/32 to 5/32 inches (2mm to
4mm). Surfaces are smooth and forms are well detailed with minimal draft angles. Products are dried in the
mold and no oven curing is needed. Due to the hot mold pressing process, the walls are somewhat more
dense. Type-3 thermoformed fiber, products closely resemble Thermoformed plastic material.
• Type-4 Molded Fiber Products – Processed
• This type is refers to molded fiber products that require some type of secondary or special treatment other than
simply being molded and cured. Examples of Type-4 are: Hot or after pressed – Die-cut or perforated – Printed –
Colored – Special mold Special slurry formulations – Embossments – Special design features – Special additives
o
Recyclability: same as any paper based packaging, biodegradable & compostable depending on
ink/glue use
Methods & strategies to achieve EPS
removal.
 Methods & strategies to achieve EPS removal
o
o
Molded fiber
o Replacement pieces can be made to match existing EPS pieces
or
o Replacement pieces can perform similar protection but in a different layout
Molds
o Molded fiber pieces are created via specialty molds. Mold pricing is typically higher than
EPS mold cost.
Solution example: Existing EPS
Solution example: Molded fiber redesign
Methods & strategies to achieve EPS
removal.
 Methods & strategies to achieve EPS removal
o
o
Paper Cushioning
o Replacement pieces can be made to match existing EPS pieces
or
o Replacement pieces can perform similar protection but in a different layout
Molds
o Paper cushioning does not need molds. Best course of action is to review paper supplier
capabilities to deliver needed pieces to create protective packaging pieces.
Solution example: Existing EPS
Solution example: Paper Cushioning redesign
Methods & strategies to achieve EPS
removal.
 Methods & strategies to achieve EPS removal
o
o
Paper Honeycomb
o Replacement pieces can be made to match existing EPS pieces
or
o Replacement pieces can perform similar protection but in a different layout
Molds
o Paper cushioning does not need molds. Best course of action is to review paper supplier
capabilities and options offered. Formed pieces and honeycomb wrapping are both viable
options.
Solution example: Paper Honeycomb redesign
Formed
Wrapping
Methods & strategies to achieve EPS
removal.
 Methods & strategies to achieve EPS removal
o
o
Expanded Polyethylene (EPE)
o Replacement pieces can be made to match existing EPS pieces
or
o Replacement pieces can perform similar protection but in a different layout
Molds
o Molds are required for more complex/specialized shapes. Most EPE suppliers have
standard block shapes that can be bought off shelf too.
o MOLDED EPE is not a viable solution for China based vendors as molded EPE
suppliers are very rare in China.
o EPE wrap, sheets, blocks, and corners are available in China.
Solution examples: EPE foam, blocks, stacked/glued
sheets for complex shapes in place of molds
Molded EPE
Methods & strategies to achieve EPS
removal.
 Methods & strategies to achieve EPS removal - Additional possible solutions
 NOTE: Target is open to non-EPS solutions not presented in this document
o
o
o
STOROpack PAPERplus – kraft paper in various shapes
Bioplastic ecovio® EA 200 – custom molds from BASF is made from 80 percent bio-based
materials & certified compostable link
https://www.ranpak.com/solutions/
STOROpack PAPERplus
Ecovio EA 200 molded
Methods & strategies to achieve EPS
removal.
 Methods & strategies to achieve EPS removal - Additional possible solutions
 NOTE: Target is open to non-EPS solutions not presented in this document
o
o
Northstar Fiber - Uses crop waste not trees to produce 100% compostable packaging
Cost - ~ 20% above EPS
Northstar Fiber
Methods & strategies to achieve EPS
removal.
 Methods & strategies to achieve EPS removal - Additional possible solutions : Corrugate replacement of EPS
 NOTE: Target is open to non-EPS solutions not presented in this document
o
Diecut corrugate inserts made to specific product dimensions
o Layering of product pieces
o Sleeves for added protection
Methods & strategies to achieve EPS
removal.
Methods & strategies to achieve EPS removal - Additional possible solutions : Corrugate replacement of EPS
 NOTE: Target is open to non-EPS solutions not presented in this document
 Components
-
Corrugate stand holder(Bottom Pad )
Insert card
Corners x 4pcs
Top filler
Greyboard tube（kraft top）
Outer box
 Assembling
- Step 1: We prepare a stand holder for the pot, it is used to fix the position of the pot and reduce some external impact
- Step 2: We use insert card to create some buffering between the pot cover and body to keep them from hitting into each other.
Methods & strategies to achieve EPS
removal.
- Step 3: We put the stand holder and pot with insert card and bellyband into an outer box
- Step 4: We put 4 pcs of corner fillers next to the pot for making it less rocking during transit
- Step 5: We put a top filler on top of the pot, then we put a greyboard cylinder on the top filler, when we seal the outer box, this cylinder will be
next to the flap of the box. Therefore, the space between the outer box and the product can be filled up, no room to let the product shaking
during transit.
Greyboard tube
Remark:
We did not have a paper tube in
right size in hand, so we take
the carton box tape for demo