docSustainability Through Flexible Packaging
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Sustainability Through Flexible Packaging
Sustainability Through Flexible Packaging About Ampac innovation in action About Ampac Broad Global Presence innovation in action About Ampac Ampac Business Units Flexibles Retail innovation in action Security Global Market Expansion Manufacturing Centers 1997 2001 2011 1 2 14 Countries with Operation USA USA USA, China, Southeast Asia, UK, Switzerland and Germany People 210 440 1,500 Retail and Food Packaging Food, Medical, Pharmaceutical, Retail and Security Packaging Markets Retail Packaging Innovation and proactivity builds customer relationships and provides growth innovation in action Global Market Expansion Flexible Products: Pouches & Laminations Flexible Products: Coextruded Films Security Packaging Products Specialty Retail Products 2000 innovation in action 2002 2004 2006 2008 2011 Ampac Operations Flexible Packaging Solutions Film coextrusion Printing – Rotogravure, flexographic, high process Laminating Pouching innovation in action Ampac Operations Core Markets Pharmaceutical / Medical Retail Financial Institutions / Banks innovation in action Food Pet Food Ampac Operations Flexible Packaging Solutions EZ-ZIP® Key Attributes and Benefits Improved Filling Efficiencies – zipper on one side of the pouch prevents issues filling through zipper or opening zipper Easy Opening – straight and easy tear; no tearing into product or need for scissors Easy Re-open – header offset provides easy re-access to zipper Improved Branding – package remains intact Header remains to provide branding and copy space, easy access space for date coding that remains with the pouch. Easy for consumer innovation in action Ampac Operations Flexible Packaging Solutions Butterfly Pack Key Attributes and Benefits Unique Unit Dose Dispensing – flatter rigid package with controlled single dose dispensing Broad Market Reach – food and non-food, medical, health and beauty, cosmetics Filling / packaging machine partner – Easypack Solutions innovation in action Sustainability innovation in action Sustainability “Sustainable development meets the needs of the present without compromising the ability of future generations to meet their own needs” (U.N. 1987 World Commission on Environment and Development). Sustainability includes the concept of the Triple Bottom Line: the interpretation of financial, environmental and societal aspects of an organization and business decisions. innovation in action Sustainability Oxodegradable PE with catalyst additive; catalyst causes the PE to break down in the presence of oxygen, heat, or light but PE fragments remain Compostable Compost satisfactorily, including biodegrading at a rate comparable to known compostable materials. Assure the degradation will not diminish the value or utility of the compost – meet ASTM D6400 Renewable Produced with renewable (generally non-petroleum) materials. Can be 100% or partially renewable. Recyclable Products that can carry a #2, #4 or #5 symbol or that can be certified through partner programs (Terracycle, Trex, etc.) Improved Process Produced using less natural resources (energy) than a comparable product (e.g. solventless laminate vs. solvent uses 86% less energy) innovation in action Packaging Market innovation in action U.S. Packaging Industry Overview Total US Packaging $136 Billion Misc Rigid Plastics & Bottles 16% Glass 3% Others 15% Metal Cans 12% Flexible 18% Paperboard 11% Corrugated 24% U.S. Flexible Packaging End-Use Markets $ 25.9 Billion Flexible Packaging: “Any package or part of a package that can readily change shape. It includes packaging utilizing paper, plastics, film, foil or any combination of these materials.” innovation in action © 2010 Flexible Packaging Association Source: Latest U.S. Census Bureau data & Flexible Packaging Association estimates 2009 Stand-up Pouches Expected Grow NA Food and Beverage Pouch Market 2009-2014 14.0 12.0 11.5 11.0 10.4 12.1 12.4 12.8 Billion Units 10.0 8.0 6.0 4.0 2.0 0.0 2009 *Year on year growth % innovation in action 2010 2011 Source: Euromonitor 2011 2012 2013 2014 Stand-up Pouch growth ***4.2% and $2.4 Billion*** Flexible Packaging and Sustainability innovation in action Some Obvious Advantages of Flexible Packaging Can Be Customized to Meet Product Needs Offers Great Shelf Appeal Conveys Product Information Provides Consumer Convenience Reclosability Microwaveability Extended Shelf Life innovation in action © 2010 Flexible Packaging Association Less Obvious Advantages of Flexible Packaging FPA research confirms that flexible packaging: Lighter weight, provides better product-to-package ratio Efficient storage (warehouse, retail, home) Fewer trucks on the road and less emissions Uses fewer resources and less energy over life cycle Results in less CO2 emissions Reduces Product Spoilage & Waste innovation in action © 2010 Flexible Packaging Association FPA/Battelle Streamlined Life Cycle Assessment 20 © 2010 Flexible Packaging Association innovation in action Food Chain Energy Consumption Of total energy used in the food chain 50% used in food production 10% on transport to stores 10% to make primary, secondary and tertiary packaging 30% is used by shoppers to drive to the shops and store and cook food innovation in action packaging, 10% transport & retailing, 10% drive to stores, storage, cooking, 30% food production, 50% Source: “Packaging in Perspective” prepared by the Advisory Committee on Packaging (UK) Flexible Packaging Reduces Waste Less Packaging Weight = Less Waste in the First Place Plus Greater Transportation Efficiencies Bag-in-a-box packaging produces 2.9 times more MSW than stand-up flexible pouches. Stand-up flexible pouches are 63% less weight compared to bag-in-a-box packaging. Stand-up flexible pouches are 96.7% less weight than glass bottles and 40.4% less packaging weight than aluminum cans. Glass bottle is 20 times more landfill material by weight. innovation in action Source: FPA Case Studies, 2009 Flexible Packaging Uses Less Resources Saves transportation miles & fuel consumption 60 pounds of beverage innovation in action = 50 pounds of glass = 6 pounds of Rigid PET = 3 pounds of aluminum = 1.5 pounds of Flexible plastic Sources: Dow Presentation; FPA Case Studies, 2009 Flexible Packaging Improves Transportation Efficiency Reducing Fossil Fuel Consumption and CO2 emission Lessening Highway Wear/Tear and Congestion (Pasta Sauce Flexible Pouch Example) 26 Truckloads of Unfilled Glass Jars innovation in action = One Truckload of Unfilled Plastics Pouches = Less Fuel consumed & Less emissions Source: DuPont Awards for Packaging Innovation Flexible Packaging Sends LESS to the Landfill Beverage Packaging Example: Product Weight (g) Package Weight (g) Package Wt per 100 g Product (g) Recycle Rate Glass Bottle & Metal Cap 236 198.4 83.9 35% Plastic PET bottle & Cap 236 22.7 9.6 37% 63% 6.0 Aluminum Can 236 11.3 4.7 49% 51% 2.4 199 5.7 2.8 0% 100% 2.8 Flexible Stand Up Pouch innovation in action To MSW Landfil l 65% MSW Landfill per 100 g Product (g) 54.5 Sources: FPA Case Studies, 2009; EPA 2007 MSW Report Beverage Packaging Packaging Weight per 100g Product MSW Landfill per 100 g Product* Energy Consumption MJ/8 oz Emissions Kg CO2 e/8 oz Beverage Packaging Product Weight Packaging Weight ProducttoPackaging Ratio Glass Bottle & Metal Cap 8 ounces (236 g) 198.4 g 1:1 83.9 g 54.5 g 3.36 0.29 Plastic PET Bottle & Cap 8 ounces (236 g) 22.7 g 10:1 9.6 g 6.0 g 3.00 0.18 Aluminum Can 8 ounces (236 g) 11.3 g 21:1 4.7 g 2.4 g 0.99 0.08 6.75 ounces (199 g) 5.7 g 35:1 2.8 g 2.8g 0.45 0.02 Stand-up Flexible Pouch Product assumed to be water *Recycling rates factored: U.S. EPA 2007 MSW Report. Cradle-to-grave life cycle energy consumption and CO2 emissions data developed for FPA by Battelle Memorial Institute. Packaging weight, product weight, and product-to-packaging ratio calculated by Packaging & Technology Integrated Solutions, LLC (PTIS) innovation in action © 2010 Flexible Packaging Association Flexible Packaging End-Of-Life Cycle Options Most Preferred Source Reduction and Reuse Flexible Packaging Supports Source Reduction (EPA’s most preferred waste management strategy) Recycling Composting Waste to Energy Least Preferred Landfill or incineration with no energy recovery U.S. EPA Solid Waste Management Hierarchy innovation in action Flexible packaging offers significant potential for energy recovery from waste. Waste to Energy: A Renewable Source of Energy Favors Flexible Packaging The EPA recognizes waste to energy as a clean, reliable, renewable source of energy.* The U.S. converts only 29 million tons of solid waste to energy annually. This is equivalent to a savings of 29 million barrels of oil or 10 million tons of coal annually. 1 ton combusted MSW: MSW = Municipal Solid Waste = = 1/3 ton coal 1 barrel oil *Letter from U.S. EPA to Integrated Waste Services Association, February 14, 2009 innovation in action Source: FPA/Battelle Study, 2009 WTE Generates Less Emissions Currently WTE facilities emit less GHG emissions than fossil fuel energy plants Fuel Carbon Dioxide Sulfur Dioxide Nitrogen Oxides (lbs/MW.h) Energy from Waste 837 0.8 5.4 Coal 2249 13 6 Oil 1672 12 4 Natural Gas 1135 0.1 1.7 Source: FPA/Battelle Study 2009, “Comparison of Air Emissions from Waste-to-Energy Facilities to Fossil Fuel Power Plants,” Jeremy O’Brien, Solid Waste Authority of North America, www.swana.org innovation in action © 2010 Flexible Packaging Association Examples innovation in action Migration from Rigid to Flexible What is the next package format as categories evolve? innovation in action Rigid Functionality with Flexible Benefits Ecologic Pouch Key Attributes and Benefits Recyclable Outter shell 100% recycled board In side No. 4 pouch and fitment. Broad Market Range – any “flowable” product; food and non-food. Seventh Generation Laundry Soap Launch May 2011 innovation in action Rigid Replacement Retort Pouch vs. Glass Jar – Packaging Weight 33 innovation in action Rigid Replacement Pouch vs. Glass Jar – Walmart Scorecard Impact 100% Percent Change 80% 60% 40% 20% 0% -20% Packaging Knowledge Group LLC innovation in action 34 Rigid Replacement innovation in action Rigid Replacement Box Pouch Less weight that traditional box with liner Better cube utilization than bottom gusset pouch Truly flat bottom for better stand up display Window displays front, sides or bottom innovation in action Rigid Replacement Reusable Flexible Water Bottle Vapur® Anti-Bottle Replaces disposable rigid PET water bottles Refill with drinking water from tap Rolls up and fits into pocket when empty Antimicrobial inner layer Dishwasher safe innovation in action Rigid Replacement innovation in action Recycleable Stand-up Pouch No. 2 PouchTM HDPE pouch, can be labeled with SPI number 2 triangle Easier to recycle compared to multi-ply, laminated pouches; recyclable with plastic, retail shopping bags Positive step for environmentally influenced purchasing decisions Approved by Trex® Company for post consumer recycling into outdoor decking and railing processor of 70% of all plastic bags recycled in the US Good MVTR Barrier Resealable zipper High definition flexo printing Available in roll stock for FFS packaging innovation in action Compostable Bio Pouch Key Attributes and Benefits Biodegradable/compostable stand-up pouch with resealable zipper Meets ASTM D6400 requirements for municipal composting 50% Renewable resource (cellulose) content Made with Innovia Natureflex™ films Saran coated for oxygen and moisture barrier innovation in action Thank You! 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