One Planet Packaging
Powerpoints
1. An introduction to packaging
2. Packaging trends
3. Sustainability and the environment
4. Designing for sustainability
5. Sustainable packaging
6. Packaging materials life cycles
7. Packaging policies and regulations
8. Packaging materials
9. Case study: What is right-sizing?
10. Functional performance tests
Index
An introduction
to packaging
PowerPoint one
Index
Origins of packaging
The ‘first’ examples of
packaging were natural
objects – shells, gourds and
leaves – used to contain
food and drink so that it
could be consumed in a
place away from where it
was obtained.
Packaging functions
•
•
•
•
•
•
protect
inform
contain
transport
preserve
display
Packaging categories
• primary packaging
• secondary packaging
• transit packaging
Primary packaging
Package labelling
refers to the graphics
and text that provide
information about
product contents, and
directions for handling
and use
Primary packaging surrounds the product and features
labelling.
Secondary packaging
Secondary packaging is the box or crate into which a number
of primary packages are placed for ease of manual movement
of products. Some secondary packaging is also used to display
products.
Transit packaging
Transit packaging is the
base pallet, strapping
and wrapping used to
bundle the boxes or
crates for transport and
distribution.
Shipping containers
Transit packaged products are placed in shipping containers
for long-distance transportation and distribution.
Packaging manufacturing
About 65% of packaging used
in the UK is produced in the
UK. (The Packaging
Federation, 2010)
How has packaging changed?
function
protect
inform
contain
transport
preserve
display
pre-industrial
period
today
Packaging
trends
PowerPoint two
Index
Trend
Mass of packaging per person
in:
• UK – 147 kg/year
• Germany – 158 kg/year
• Netherlands – 172 kg/year
• France – 162 kg/year
The total mass of packaging used in the UK and Europe is
increasing.
Increasing packaging
Single-serve packaging and ready meals are convenient for
consumers, but use more packaging.
Increasing packaging
Luxury packaging involves layers of packaging or the use of
unusual packaging materials perceived to convey status.
Packaging and waste
• Half of all the
packaging produced
ends up in our homes.
• Primary packaging
makes up 20 percent of
all household solid
waste.
Every year, more than 10 million tonnes of packaging are used
in the UK.
Recycling packaging materials
More than one-third of
the food packaging in
an average shopping
trolley cannot be
recycled.
Many materials used for packaging cannot easily be recycled,
and others become contaminated by food residues and
cannot be recycled.
Reducing packaging
Bottle manufacturers have redesigned
milk bottles to be 65 percent lighter. This
uses less glass and makes the product
lighter and less expensive to transport.
Reducing packaging
Can manufacturers have redesigned steel cans to be 61
percent lighter, saving metals and making the product lighter
and less expensive to transport.
Packaging and lifestyle
What is the relationship between the amount of packaging
and lifestyle?
Waste-free packaging
Is it possible to develop
practical and cost-effective
packaging that is wastefree?
Sustainability and
the environment
PowerPoint three
Index
Sustainability
Sustainable communities are
described as places where people
lead lives of quality and dignity
without damaging the ecological
systems responsible for clean air,
safe water, healthy foods, shelter
and human health.
Sustainability is the goal of maintaining a human society over
time in ways that are fair and just for all people and do not
damage the environment and its biodiversity.
Sustainable development
The United Nations
Environment and Development
Programme states that human
well-being is central to its
efforts to promote sustainable
development.
A plan for the development of communities that
balances the importance of a vibrant economy and
sustainability.
Weak sustainability
environment
society
economy
The three elements of sustainable development – the
environment, society and the economy – are competing
interests. The point where they come together represents
sustainable development.
Weak sustainability
environment
society
economy
This model accepts that many aspects of development serve
the economy, society or the environment alone. It suggests
that technology can be a substitute for a damaged
environment.
Strong sustainability
environment
society
economy
The environmental element of sustainable development is
viewed as the common ground where society and the
economy interact and develop.
Strong sustainability
environment
society
economy
Development cannot damage the environment; a healthy
environment is fundamental to a just and fair society and a
vibrant economy – now and in the future.
One planet living
The phrase ‘one planet’ refers to the
level of natural resource use required
for everyone on the planet to have
access to their ‘fair share’. Today, a
small number of people use the
majority of the earth’s resources.
WWF-UK and BioRegional developed 10 principles for ‘one
planet living’ that designers can use to plan places and
products that promote sustainable development.
1. Zero carbon
How can
packaging be
‘zero carbon’?
The activity must produce net zero carbon dioxide emissions.
Net zero means that the activity produces no carbon dioxide,
or takes measures to remove the carbon dioxide it produces.
2. Zero waste
How can packaging be
‘zero waste’?
All materials must be used cleanly and recycled cleanly in a
continuous cycle; or they must be composted to re-enter
ecological cycles.
3. Sustainable transport
How can
packaging achieve
‘sustainable
transport’?
The movement of materials and products must be done in
ways that are good for people and the environment.
4. Local and sustainable materials
What types of packaging
can be produced using
‘local and sustainable
materials’?
Meet consumer demands by using materials that are locally
sourced and use locally available technologies for recycling
and reuse.
5. Local and sustainable food
What role can packaging
play to promote ‘local and
sustainable food’?
Promote and consume foods that support regional agriculture
and food industries, and minimise their use of non-renewable
natural resources in the form of fossil fuels used for transport
and fertilisers.
6. Sustainable water
What role does water play
in packaging production
and recycling and how can
it be sustainable?
Water use that promotes human health and prevents water
pollution, depletion of fresh water, and harm to aquatic and
marine ecosystems.
7. Natural habitats and wildlife
What role can packaging play in
protecting and restoring ‘natural
habitats and wildlife’?
The harvesting or mining of natural resources, and the
construction of transport routes, factories, warehouses and
retail centres should not damage or degrade natural habitats
or harm wildlife.
8. Culture and heritage
How can ‘culture
and heritage’ be
used to improve
packaging?
Economic activities should honour and protect the culture and
heritage of the communities they affect, and local knowledge
should be used to make decisions.
9. Equity and fair trade
What role can packaging play in
promoting ‘equity and fair
trade’?
Everyone involved in the development, distribution, sales and
recycling of products must be treated and paid fairly and have
opportunities for a dignified life.
10. Health and happiness
What role can packaging
play in addressing
excessive consumption
and promoting ‘health
and happiness’?
Beyond the consumption of goods and services to meet basic
human needs, there is no correlation between consumption
(wealth) and happiness.
Designing for
sustainability
PowerPoint four
Index
Designing for weak sustainability
Can you name a packaging
material that achieves weak
sustainability?
Consider the economic, social and environmental strengths
and weaknesses of their designs, but compromise to minimise
potential environmental harm.
Designing for strong sustainability
Can you name a
packaging material that
achieves strong
sustainability?
Consider the economic, social and environmental strengths
and weaknesses of their designs, but do not compromise and
achieve environmental protection as a design priority.
Cyclic solar-safe design criteria
Practical design criteria for
judging the strengths and
weaknesses of a design’s
sustainability were developed
by Edwin Datschefski in 1998.
Cyclic
The problem with most
recyclable materials is
that their quality
degrades when they
are recycled.
What packaging
materials could be
considered ‘cyclic’?
The product must be made from organic materials that can be
recycled or composted repeatedly.
Solar
What are the challenges of
creating packaging that
achieves the ‘solar’
criteria?
What role can packaging
designers play in improving
the ‘solar’ performance of
packaging?
The product must use solar or other renewable energy
throughout is development, distribution, use and recycling.
Safe
Why are the ‘safe’
criteria so important to
packaging?
The product must be nontoxic for humans and other
organisms, and no toxic chemicals can be used in
manufacturing or recycling.
Efficient
Why is the ‘efficient’ criteria equally important to both the
environmental and economic aspects of packaging?
The production and use of the product should require 90%
less material, energy and water compared to similar products
manufactured before 1990.
Social
What are the challenges of
creating packaging that achieves
the ‘social’ criteria?
What role can packaging
designers play in improving the
‘social’ performance of
packaging?
The product, and the development and manufacture of the
product, must not jeopardise the rights, health or livelihoods
of individuals or communities.
Compare
similarities
One planet
living principles
vs.
Cyclic-solarsafe design
criteria
differences
Sustainable
packaging
PowerPoint five
Index
Sustainable packaging
Packaging that is functional, cost effective and meets
sustainability principles or design criteria.
Precautionary principle
Name a packaging
product you think
would not have been
made if the designer
had followed the
precautionary
principle.
An obligation for designers to prove that a product, through
its manufacture, use or disposal poses no negative
consequences for people or the environment.
Strategies for sustainable
packaging
Renewable and compostable
materials
Examples
• Bioplastics made from corn,
potato, wheat, or dairy
polymers
• Paper and cardboard from
sustainable managed forests
• Cellulose film
Recycled and recyclable materials
Examples
• Paper and cardboard made from recycled fibre or
moulded pulp
• Recycled and recyclable plastics like HDPE and PET
Design for reuse
Examples
• Reusable and recyclable
crates and pallets
• Re-sealable plastic
containers
• Return system for customer
refills
Design for recycling
Examples
• Packaging made from a
single material (including
labels and closure system)
• Packaging made from
materials that are commonly
collected for recycling
• Packaging with prominent
recycling symbols
No toxic inks, paints or adhesives
Examples
• Print with inks that do not contain
toxic compounds (volatile organic
compounds – VOCs)
• Use paints and inks that do not
contain heavy metals or other toxic
compounds
• Use adhesives that do not contain
toxic compounds
No secondary packaging
Example
• Use only primary
packaging and
transit packaging
Reduced material volume
Examples
• Inflatable pouches to fill
package voids
• Refills in pouches
• Lightweight bottles and cans
Challenges
What are the barriers that prevent packaging
designers and manufacturers from adopting all
of these strategies?
Packaging
material life cycles
PowerPoint six
Index
Packaging material life cycle
Stage 1
Stage 8
Designing
Disposing
Stage 2
Extracting
Stage 7
Stage 3
Using
Manufacturing
Stage 6
Stage 4
Retailing
Filling
Stage 5
Distributing
The process that describes how packaging materials are
created, manufactured, used and disposed of, recycled or reused. Each stage has potential economic, social and
environmental costs and benefits.
Stage 1: Designing
Why is this the
most critical stage
in sustainable
packaging?
What are the
• economic
• human, and
• environmental
costs and benefits at
this stage?
The designer creates a plan for packaging that meets the
functional requirements like cost and durability, as well as
sustainable design principles or criteria.
Stage 2: Extracting
What are the
• economic
• human, and
• environmental
costs and benefits at
this stage?
The raw materials are harvested
from renewable sources like
forests, or mined from the earth,
in the case of metals or oil-based
plastics.
Stage 3: Manufacturing
What are the
• economic
• human, and
• environmental
costs and benefits at
this stage?
Machinery, energy and water are typically involved in the
processes that turn raw materials like wood, aluminium and
oil into packaging materials like paper, tin and plastic; and
then turn these materials into boxes, bottles, bags and other
forms of packaging.
Stage 4: Filling
What are the
• economic
• human, and
• environmental
costs and benefits at this stage?
Both machines and human labour
are involved in placing products in
primary packaging, placing primary
packages in secondary packaging
and stacking and securing secondary
packaging on transit pallets.
Stage 5: Distributing
What are the
• economic
• human, and
• environmental
costs and benefits at
this stage?
When the products are packaged, they are moved into
warehouses for storage and/or transported to the customer
for use or retail. Some products require controlled storage
environments, like refrigeration.
Stage 6: Retailing
What are the
• economic
• human, and
• environmental
costs and benefits at this stage?
Most packaged products are sold
through retailers. Products may have
special storage and display
requirements, like refrigeration, and
may have a limited shelf life.
Stage 7: Using
What are the
• economic
• human, and
• environmental
costs and benefits at
this stage?
Once purchased by a consumer,
packaging may provide short- or
long-term storage for the
product. It may feature directions
for product use and package
recycling.
Stage 8: Disposing
What are the
• economic
• human, and
• environmental
costs and benefits at
this stage?
When the packaging is no longer needed, it can be re-used,
recycled, sent to landfill or incinerated for energy recovery.
Packaging policy
and regulations
PowerPoint seven
Index
Statutory policies
Statutory polices are required by law.
The design stage is the most
important stage for insuring
compliance with regulations.
Code of practice
Code of Practice
For optimising
packaging and
minimising waste
A code of practice is an agreed
set of standards designers
voluntarily use to develop
packaging, and that companies
follow when manufacturing
packaging.
World Packaging Organisation
The WPO recognises that over packaging is bad
for business and bad for the environment. They
ask their members to voluntarily follow their
sustainable packaging recommendations.
European Commission
The European Commission,
introduced the Producer
Responsibility Obligation in 1997
set an ambitious goal of recovering
a minimum of 79% of all packaging
materials by 2017.
Department for Environment,
Food and Rural Affairs
Defra introduced a new waste
strategy in 2011 that encourages
packaging designers and
manufacturers to optimise
packaging and maximise
packaging recycling potential.
British Retailers Consortium
In 2009, the BTC introduced the ‘on-pack recycling label’
designed to inform consumers about the likelihood that a
particular item of packaging will be collected for recycling in
their area.
Greenwash?
What responsibilities do packaging designers and
manufacturers have to prove their claims of ‘environmentally
responsible’ packaging?
Packaging
materials
PowerPoint eight
Index
Materials
Most packing contains a
number of different materials,
although this may make it
more difficult to recycle.
The most commonly used
packaging materials in the UK
are:
• paper and board (43%)
• plastic (20%)
• glass (19%)
• steel and aluminium (14%)
Selecting the right material
Material selection is based on:
• technical properties (strength, flexibility, etc.)
• fitness for purpose (moisture barrier, cushioning, etc.)
• availability
• manufacturing capability
• cost
• environmental impact
• regulations
Paper and cardboard
Paper and cardboard are
derived from trees. The
extent to which the forests
are properly managed
affects the environmental
sustainability of paper as a
packaging material.
Paper and cardboard recycling
Paper and cardboard
contaminated with food
residue – like pizza boxes –
cannot by recycled. They can
be home composted.
Paper and cardboard cannot be recycled indefinitely. When
paper is recycled the fibres get shorter. New material with
longer fibre length must be added to recycled material to
make office-quality paper.
Designing with paper
Consider:
• designs that use less paper or cardboard
• designs that can be reused
• using materials with high recycled content
• using mechanical locking instead of staples or glue
• labelling that states where the wood came from and how the
forest was managed
• labelling that informs consumers that the packaging can be
recycled
Metals
The metals most commonly used for packaging are steel and
aluminium. Both of these rely on environmentally destructive
mining practices to obtain new materials.
Metal recycling
Recycling aluminium cans
saves 95 percent of the
energy used to make
aluminium cans from virgin
ore.
Aluminium and steel are infinitely recyclable, and do not loose
their quality as a result of recycling.
Designing with metals
Consider
• designs that use less metal – cylindrical shapes with straight
vertical sides use less material
• designs that use thinner metals – this reduces weight for
transport
• using metals made from recycled materials
• labelling that informs consumers that the packaging can be
recycled
Glass
It takes one tonne of
water to produce one
tonne of glass.
Glass manufacturing is energy intensive and requires large
volumes of water.
Glass recycling
When the demand for recycled
glass is low, many service providers
use a single collection bin. This low
quality cullet is used as an
aggregate in bituminous concrete.
Glass can be recycled indefinitely, but it must be colour sorted
to maximise its recycling potential. Because so many products
in glass containers are imported into the UK, more bottles are
recycled than are needed.
Designing with glass
Consider
• designs that use less glass – cylindrical shapes with straight
vertical sides use less material
• designs that use thinner glass – this reduces weight for
transport
• a design that can be reused
• a design made from recycled glass
• use organic labels that burn off easily during recycling
• labelling that informs consumers that the packaging can be
recycled
Plastics
Plastics are a group of
materials, typically made
from petroleum-based
compounds. They can
also be made from
organic materials like
plant starch.
There are more than 50
different types of plastic and
hundreds of varieties.
Plastic recycling
An international system of coding
is used to identify types of
petroleum-based plastics for the
purpose of recycling. SPI resin ID
codes 1 and 2 are most widely
recyclable.
Bio-plastics can be composted,
but not in home composters.
Designing with plastic
Consider
• designs that use less plastic – cylindrical shapes with straight
vertical sides use less material
• designs that use thinner plastic – this
reduces
weight for transport
• a design that can be reused
• a design made from recycled plastic
(SPI resin
codes 1-2)
• avoid coloured plastic (they’re more difficult to recycle)
• labelling that informs consumers that the packaging can be
recycled
Biodegradable materials
‘Ecocradle’ is a Styrafoam substitute
corner protector that is grown rather
than manufactured. Fungi are grown in
a waste grain mixture and give the
material its unique structure.
Biodegradable packaging materials are typically made from
agricultural waste by-products, such as grain husks.
Image from http://uo-gpdn.ning.com
Composting biodegradable
materials
Biodegradable materials can be
added to home compost piles,
although some require industrial
composting technologies that
achieve higher temperatures.
Designing with biodegradable
materials
Consider
• designing a new biodegradable
material
• a design that uses biodegradable
materials
• labelling that informs consumers
that the materials can be home
composted
Other materials considerations
Packaging materials themselves are just one consideration.
Other things to consider include:
• Use of composite materials
Packaging made from composite materials are more difficult to recycle
• Other secondary materials
Packaging involves the use of adhesives, tapes, inks, coatings, etc. that all have
sustainable alternatives
• Packaging machines
Manufacturing packaging involves the construction of complex machines that use
resources and energy
Consumer perspective
What role does sustainable packaging
play in consumer choice?
i2ieurope
case study
PowerPoint nine
Index
Right-sizing
Right-sizing is a packaging design principle that seeks to
reduce the amount of packaging, save money, and reduce the
impact on the environment by designing packaging that is the
‘right size’ for the product.
The product
An eco-product that provides light without the use of
batteries. One minute of winding provides 20 minutes of light.
Original primary packaging
Original primary
packaging mass
Plastic
Paper
Total
23 g
10 g
33 g
The product was placed in a clear plastic package, with a
paper insert providing product information.
Original secondary packaging
Original secondary packaging
mass
Plastic
Paper
Total
0g
524 g
524 g
Tape
1460 mm
Twelve primary packaging units were placed in each
secondary packaging box, which also functions as a point-ofsale display.
Original transit container
Original packaging mass
per unit
Total
76.67 g
3,024 secondary packages are manual loose loaded into a
lorry container.
Problems
24 lorries deliver 870,912 products
• Inefficient use of container space
• High cost for excessive packaging
• Negative environmental impact because the plastic packaging
was not recyclable
New primary packaging
New primary
packaging mass
Plastic
Paper
Total
0g
53 g
53 g
20 g heavier than the
original primary
package
• Eliminate plastic and use only corrugated carton
• Reduce the overall size of the primary packaging
New secondary packaging
New secondary packaging
mass
Plastic
Paper
Total
0g
182 g
182 g
Tape
290 mm
342 g lighter than the
original secondary
package
In the new version twelve primary packaging units are placed
in each smaller secondary packaging box, which also functions
as a point-of-sale display.
New transit container
New packaging mass per
unit
Total
68.17 g
8.5 g lighter per unit
6,480 secondary packages are manual loose loaded into a
lorry container.
Solution
12 lorries deliver 933,120 units
Compared to:
24 lorries delivering 870,912 units
• Total packaging materials used is reduced.
• All packaging materials can easily be recycled.
• Reduced transport fuel use and cost.
Functional
performance
tests
PowerPoint ten
Index
1. Drop
This test should assess the
ruggedness of the secondary
packaging and its ability to
protect the primary packaging
and product from damage.
It should simulate the effects
of sorting machines,
conveyors, and manual
handling and stacking that
may result in short, sharp
vertical drops.
2. Inclined impact
This test should assess the
ability of combination
packaging to withstand side
impacts, such as those
associated with manual
handling and sudden starts
and stops during vehicle or
train transit.
3. Pest prevention
This test should assess the ability
of the packaging to prevent pest
damage that may be caused by
rodents, insects or microorganisms to primary packaging or
the product.
4. Compression strength
This test should
simulate the
temporary
compression
associated with
stacking during
transport and
distribution.
.
5. Stack load
This test should
assess the stability
of the combination
packaging and
packaging
adhesives under
compression
associated with
long-term storage
or warehousing.
6. Weathering
This test should assess
the ability of
combination
packaging to
withstand changes in
temperature,
moisture, and direct
sunlight exposure
associated with
transport and storage.
7. Vibration
This test should assess
the ability of packaging
to withstand vibration
associated with
transport.
8. Disassembly
This test should assess
the disassembly of
combination
packaging for the
purpose of recycling
the component
materials.
9. Recyclability
This test should assess
the sustainability of all
the component
materials used in the
combination
packaging.
10. Cost effectiveness
This test should assess the cost of the
packing as a percentage of the cost of
the product inside the packaging.
It should make an effort to estimate
the direct costs that would be
incurred over the life cycle of the
combination packaging.