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Plastic packaging - and life is easier
and life is easier French Plastic Packaging Association > plastic packaging A modern solution in line with sustainable development Plastic packaging makes a far-reaching contribution to the quality of life and wellbeing: it protects, prevents wastage and product loss, keeps things clean and makes daily life easier. Plastic packaging, through the diversity of its solutions and applications, plays a major role in modern life. The wide range of materials, conversion technologies, graphics and technical qualities means plastic packaging is found in every sector of industry and retailing. It is active, positive player in the product chain through to end users, especially consumers. Plastic packaging is appreciated for its many daily contributions to society in terms of safety, comfort and modernity. Plastic should also be trusted as a social responsible packaging material. Light with constant weight reductions, free of heavy metals, recyclable and recycled, its energy can be recovered when incinerated. Plastic packaging is suited to responsible consumption. It is intended to be used advisedly and disposed of carefully. Plastic packaging anticipates, innovates and is now recycled on an industrial scale. Work is being done to diversify its raw materials and develop new packagings based on renewable resources. Plastic packaging meets contemporary society’s concerns for saving resources, making maximum use of products and encouraging good citizenship while giving as many people as possible safe access to many products and to a satisfactory standard of living. > contents plastic packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 3 > the many sides of plastic packaging > conversion processes > material for every packaging type > from raw material to the end of the lifecycle... a crucial role at every stage > R&D: innovative design the role of packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 11 > benefits for users > marketing advantages > a palette of graphic techniques > safety the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 15 > prevention > reusable packaging and the environment > recovering plastic packaging • choice of recovery method • recycling • energy recovery > protecting the environment on production sites > manufacturers’ active commitment consumption sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 23 > Food > Healthcare > Perfumes - cosmetics > Industry and retailing > Cleaning products CSEMP and its members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE 31 > CSEMP - the French Plastic Packaging Association > useful contacts plastic packaging PAGE the many sides of plastic packaging Plastic packaging offers an endless range of solutions through the diversity of materials, conversion processes and printing techniques. That variety makes it suitable for every sector of industry and retailing. Plastic packaging Bags • Beakers • Big-bags • Blisters packs • Bottles • Bowls • Box pallets • Boxes • Buckets • Cans • Caps • Capsules • Closures • Compacts • Containers • Crates • Cushioning material • Drums • Cartons • Lids • Pallets • Pouches • Protective caps • Pumps • Racks • Sachets • Sheeting • Sleeves • Stretch and shrink film • Trays • Tubes • Valves… Consumption sectors Agriculture • Food • Personal care • Healthcare • Pharmacy • Perfumes & Cosmetics • Cleaning products • Industry (chemicals, oil and automotive products, construction, etc.) • Retailing and distribution... Material used PE • PP • PVC • PS • EPS • PET • Bioplastics • Other: ABS, ASA, SAN, SURLYN, PA, PC, PUR… Conversion processes Extrusion (film-sheet) • Calendaring (film-sheet) • Co-extrusion • Flat or ring die co-extrusion • Blow film co-extrusion • Blowmoulding co-extrusion • Rolling co-extrusion • Blow-moulding extrusion (hollow bodies) • Coating • Blow-moulding injection (hollow bodies) • Injection (moulded parts) • Rotational moulding (large volume hollow bodies) • Thermoforming (from extruded or calendared sheet) • EPS thermoforming (after expansion by direct gassing) • APS (after steam expansion)... Printing techniques Flexography • Galvanisation • Heliography • Hot stamping • Metallising • Vacuum metallising • Offset • Silkscreening • Pad printing • Transfer (EPS) • Varnishing... 3 PAGE 4 plastic packaging QUALITIES ■ Colour ■ Appearance ■ Shape ■ Transparency ■ Feel ■ Opacity ■ Consistency ■ Rigidity ■ Lightness diversity ■ Security ■ Reliability… ■ Flexibility PROPERTIES • Stable • Recyclable • Hygienic • Unbreakable • Divisible • Reusable • Tamper-proof and • Shocktemperature • • • changeresistant Easy to print and decorate Energy-efficient Waterproof • Insulating • Hinging • Sealable • Airtight • High fill rates … Plastic packaging firsts Some key dates 1950 1960 1961 1963 1965 1968 1969 1970 1976 1979 1990 1994 1999 2000 Plastic tube Table oil bottle with single-material closure Shrink film Engine oil can Checkout bag Plastic crate Mineral water bottle and cap Bottle rack Plastic pump for perfume market Meat tray Eco-refill Packaging with long expiry date (1 year) for ready-cooked food Bioplastic film and bag Packaging for fresh ready-to-use vegetables plastic packaging PAGE conversion processes Process Products Applications Calendaring ■ Films ■ Sheets ■ Thermoforming film ■ Bagging Extrusion ■ Films ■ Sheets ■ Labels (IML) ■ Film for food use ■ Stretch and shrink film for ■ ■ ■ ■ ■ product division, palletising Thermoforming film Sleeve Bag Sachet Tube Extrusion blow moulding ■ Hollow bodies ■ ■ ■ ■ ■ Can Bottle Container Flask Drum Injection ■ Moulded parts ■ ■ ■ ■ ■ ■ ■ ■ Tray Box Closure Crate Pallet Pump Bucket Valve Injection blow moulding ■ Hollow bodies ■ Bottle ■ Flask ■ Drum Foam expansion ■ Moulded (alveolar) parts ■ Sheets (alveolar) ■ ■ ■ ■ ■ ■ ■ ■ ■ Rotational moulding ■ Hollow bodies (large volume) ■ Container ■ Pallet Thermoforming ■ From extruded or calendared ■ ■ ■ ■ ■ sheets Other processes Lamination ■ Coating ■ Coating extrusion Flat die coextrusion ■ Embossing ■ Heat, high-frequency and ultrasound welding ■ ■ Tray Box Crate Transport crate Cushioning material Housing Thermoforming Food transport pallet Technical parts Tray Blister Box Lid Beaker 5 PAGE 6 plastic packaging a material for every type of packaging Plastics and their packaging applications and properties. Material EPS Expanded Polystyrene HDPE High Density Polyethylene VHMW-HDPE Very High Molecular Weight LDPE Low Density Polyethylene LLDPE (Linear...) RLDPE (Radically...) PA Polyamide Properties Application examples ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ light ■ isothermal multiple density simple or complex shapes mouldable ■ leak-proof mechanical strengh impact resistance EPS complexing + films shock absorption hygiene ■ insulation protection ■ trays ■ mini-crates ■ transport cases ■ protective cushioning / alveolate ■ ■ ■ ■ ■ material food transport pallets organ transfer boxes cases ■ transport trays test tubes vaccines ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ vapour barrier mouldability rigidity (for mechanical testing) impact resistance chimical inertness resistance to stress-cracking sterilisation suitable for freezing (-40° C) opaqueness low friction ■ ■ ■ ■ ■ ■ ■ ■ ■ large drums ■ screw or clip tops bottles ■ crates and cases films for postal dispatch ■ flasks drums and reusable containers pots ■ tubes ■ ampoules tamper-proof and other caps caps ■ reinforcement bars pumps ■ valves ■ drums containers ■ covers ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ vapour barrier flexibility for seals mouldability flexibility tearability sterilisation good tear resistance excellent stretchability chimical inertness transparency tactile effect alcohol compatibility sterilisable by irradiation feel ■ ■ ■ ■ ■ ■ impact and creep resistance ■ resistance to oil and grease at high temperatures ■ resistance to solvents and alkalis ■ fatigue resistance ■ resistance to wide temperature trays boxing screw or clip tops nozzles stretchable and retractable films for bundling (multiple-unit packs) and palleting ■ flasks ■ stopper seals ■ carrier bags ■ small bags ■ tubes ■ ■ ■ ■ internal stoppers food films bottles components for flexible and multilayer tubes ■ tottles ranges (-50° à +170° C) ■ humidity uptake PC Polycarbonate ■ sterilisation ■ resistance ■ transparency ■ ■ ■ ■ bottles flasks feeding bottles make-up compacts PET Polyethylene Terephtalate 씰 (A)PET (amorphous) ■ transparent ■ perfume compatible ■ shiny ■ impact resistant ■ resistant to internal pressure ■ resistant to stress-cracking ■ gas barrier ■ water and UV barrier ■ high pH ■ sensitivity ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ trays oven trays (220° C) boxes bottles lids thermoforming sheets films flasks pots blister packs capsules flexible tubes syrups lotions 씰 (C)PET (crystallised) ■ same properties as (A)PET but not transparent ■ temperature resistant (220° C) 씰 PETG (glycol) ■ amorphous, same properties as (A)PET plastic packaging PAGE Material PP Polypropylene Properties ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ rigidity (resistance to sterilisation) resistance to cold vapour barrier chimical inertness suitable for freezing (-40° C) suitable for micro-waves (+120° C) low density resistant to stress-cracking resistant to folding thermal packing contact transparency shiny ■ freezing 씰 clarified PP 씰 OPP (oriented PP) 씰 EPP (PP expanded): resistance to repeated impact PS Polystyrene Compact 씰 cristal PS ■ transparency ■ shiny ■ rigidity 씰 PS impact ■ opaque ■ impact resistance ■ shiny ■ cleavability Direct gassing ■ light ■ warm touch Application examples ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ alveolate material ■ trays screw or clip tops reusable crates and cases covers thermoforming sheets transparent films and bags bottles ■ reheatable plates pots ■ tubes ampoules service caps vaccine doses mascaras ■ pill boxes pumps ■ valves flasks films reusable wrapping ■ ■ ■ ■ trays (with stretch film) egg containers stoppers ■ covers thermoforming sheets: pots for dairy products, cups for automatic drink machines ■ plates / trays ■ boxes ■ bottles ■ films ■ flasks ■ pots ■ sticks PVC Polyvinyl Chloride ■ ■ ■ ■ ■ SAN ■ transparency ■ easy colouring ■ closures ■ make-up compacts ■ pots Other materials 씰 ABS (Acrylonitrile Butadiene 씰 EVOH (Ethylene Vinyl Alcohol Styrene) 씰 ASA (Acrylonitrile Styrene Acrylate) 씰 Copolyesters 씰 PET/PEN copolymer 씰 EVA (Ethylene-Vinyl Acetate copolymer) 씰 씰 씰 씰 Complexes Combinaison of materials using PE, PP, PVC, PET, EVOH, PVDC, aluminium, paper or cardboard ■ matching properties of different ■ flexible and rigid packaging Bioplastics Based on renewable resources (starch, flour): corn, potato, cereals, etc. and oil-based raw materials Depending on material: ■ transparent or opaque ■ rigid or flexible ■ tear and crease resistance ■ excellent stretchability ■ tactile effect inertia good stretchability excellent memory resistance to stress-cracking transparency materials: barrier, printability, sealing.... ■ combinations of almost all materials possible ■ targeting of required properties (odour barriers, opacity, perforation resistance...) ■ ■ ■ ■ ■ ■ boxes ■ bottles blister packs thermoforming sheets food-contact films ■ flasks bagging ■ capsules ■ mascaras protective caps ■ blood bags copolymer) PAN (polyacrylonitrite) PUR (polyurethane) PVDC (Polyvinylidene Chloride) SURLYN with special barrier properties ■ closures for heat sealing ■ tubes ■ packing in modified atmosphere or vacuum ■ ■ ■ ■ ■ ■ ■ ■ films bagging waste bags trays cushioning material plates boxes disposable tableware 7 PAGE 8 plastic packaging from raw material to the end of the lifecycle... Plastic packaging is optimised at every stage through constant research and development (R&D) that boosts innovation and creativity. Raw material, design, manufacturing, value in use, recovery – from conception to end of its lifecycle, plastic packaging plays its role to the full with consumers and the product itself and makes an effective contribution to protection of the environment. plastic packaging PAGE ...a crucial role at every stage Raw material Plastics derived from petrochemicals have developed and diversified. Through extensive research and development work for several decades, they have been able to fulfil more and more requirements. New materials, partly made from renewable resources, are now appearing and will gradually meet the technical characteristics needed to develop in packaging and plastic films. Plastic packaging Plastic plays a fundamental role in supporting the product through the entire chain. In this stage, plastic delivers all the required functions and its properties serve product and consumer alike. After use Plastic is recovered at the end of its lifecycle. Taking several criteria into account, the most relevant recovery method is chosen – either recycling or energy recovery. Some packaging in industrial or distribution circuits is reused several times over before being recycled. 9 PAGE 10 plastic packaging R & D: innovative design The simplicity and functionality of packaging conceal the complexity of its design. Behind its commonplace appearance, plastic packaging contains a wealth of technology treasures. Research and development (R&D) is an essential function for both the product and the consumer. It begins with design, which can be through one of two approaches depending on whether the packaging manufacturer is designing stock packaging or a specific solution at its customer’s request. Design, process, materials, printing - R&D is everywhere to ensure packaging delivers its many functions and plays its many roles. COMFORT AND CONVENIENCE attentiveness to customers ■ Grip, movements ■ Easy opening and closing ■ Hinges ■ In-pack cooking ECODESIGN factoring in environmental values ■ Reduction at source: cutting weight while maintaining suitability for use ■ Recyclability ■ Limitation of number of different materials used in the same packaging Inventive R&D MARKETING unceasing creativity ■ Packaging attractiveness: design, colours, feel… ■ On-shelf impact: ready-to-sell packaging, visibility… TECHNOLOGIES a solution for every use ■ Barrier materials (to oxygen, nitrogen…) ■ Filling in modified atmosphere ■ Tamper-evident closures ■ Container/contents compatibility ■ Anti-static properties ■ Selected additives: material optimisation ■ Clip--on, snap-on, heat sealing..: high performance and imagination ■ Anti-fogging systems ■ In-mould labelling ■ Incorporation of biocides SAFETY involvement at every stage ■ Protection against thermal or physical shocks solutions ■ Hazardous products: secure systems for children, packaging suited to transport… ■ Manufacturing hygiene: optimised shapes and materials ■ Product traceability… ■ Waterproofing plastic packaging ı the role of packaging adapting to every type of contents Possibilities are endless. Its many advantages enable every container to be purpose-designed. The right plastic and the right conversion process will be able to meet the customer’s specifications. values in use Plastic packaging protects what it sells and sells what it protects. > protect > transport > preserve > secure > ensure traceability > stand out > attract > inform > dose for the right usage > help the user PAGE Plastic packaging fits perfectly into everyday life. Its diversity means it is present in every sector of the food industry, as well as cosmetics, healthcare, cleaning products, chemicals, transport, distribution and industrial and agricultural products. It adapts to trends and constraints in the product itself as well as in filling, transport, lifestyles, user profiles and consumer habits. Thanks to plastic packaging, the product is kept intact in terms of hygiene, preservation, heat insulation and safety. Plastic packaging provides for optimum in-shelf organisation and standout, with excellent ergonomics for both consumers and industrial users. 11 PAGE 12 plastic packaging ı the role of packaging marketing advantages Plastic packaging has all the qualities needed to play a major marketing role in product development. It gives consumers their first image of the product and guides them in their choice. It has a preponderant role in allowing consumers to identify the product that meets their need. Plastic packaging is an important component of the product marketing mix and helps to win new markets. Manufacturers work on sociological and generational consumer trends to offer relevant products. Plastic packaging can be sophisticated, mass-market, junior, senior, nomadic… > design > colour > ergonomics > convenience Plastic packaging’s marketing advantages ■ Varied, innovative shapes Flexible or rigid ■ Transparency ■ Translucence ■ Opacity or colour ■ Printing quality and variety ■ Variety of tactile effects ■ Attractiveness ■ Safety ■ Plastic packaging serves the packed product with its innovation capabilities and technical skills to create a vast range of graphics, closures and dispensing systems. plastic packaging ı the role of packaging PAGE a palette of graphic techniques The varied graphic techniques for plastic packaging play a crucial role in a sector where marketing and information functions are fundamental. Graphics help to identify and customise packaging. The variety of available techniques gives great freedom of choice in both graphic quality and coverage. Every type of packaging, whether rigid or flexible, can be decorated regardless of shape (flat, spherical, cylindrical, conical, etc.). Techniques used for rigid packaging ■ Embossing Stamping ■ In-mould labelling (IML), injection, thermoforming ■ Adhesive labels ■ Galvanisation ■ Etching ■ Dry offset printing ■ Lamination ■ Deep-died material ■ Hot stamping ■ Sleeving ■ Metallising, vacuum metallising ■ Silkscreening ■ Pad printing ■ Hot transfer ■ UV varnishing ■ For flexible packaging ■ Offset Heliography ■ Flexography ■ 13 PAGE 14 plastic packaging ı the role of packaging safety Plastic packaging makes a great contribution to product safety and meets users’ different requirements and expectations in terms of innocuousness and health. Hygiene Food industry companies comply with hygiene regulations by referring to the “Guide to best hygiene practices for plastic packaging and laminate flexible packaging for food use” drawn up by CSEMP and UNITES. This tool is used to: ■ meet the food industry’s expectations, ■ control the hygiene quality of packaging, ■ use the HACCP* method in accordance with packaging users’ practices. Beauty sector companies comply with regulations in the “Guide to Good Hygiene Practices for Manufacturers of Plastic Packaging for Use in the Beauty Products Industry”, drawn up by CSEMP. * HACCP - Hazard Analysis Critical Control Point: Preventive management system for guaranteeing food safety. It identifies potential hazards (any biological, chemical or physical property that affects food safety) and specifies the measures needed to manage them. Regulations Plastic packaging and material in contact with food European and national regulations govern the use and suitability of materials in contact with food. These regulations are mainly made up of a list of authorised materials and additives. This is governed by two main principles: inertia and innocuousness of the packaging in relation to its contents. Regulations for materials in contact with food do not automatically apply to packaging for beauty products. However, on the customer’s specific request, the beauty packaging manufacturer may be led to apply those regulations, which particularly include directive 2002/72/EC. For materials in contact with medicinal products, pharmacopeia also applies. The guide contains: ■ General hygiene provisions that help to create motivation and a mindset for preventing a large number of risks. ■ Specific hygiene provisions in order to control the potential hazards related to the processes for manufacturing packaging before its end use. These measures are based on a HACCP* study. Traceability Plastic packaging manufacturers take special care over traceability. This requirement is stated in framework regulations 1935/2004/EC. The practical arrangements for their application are covered by a guide that is available in the website of the European Commission reference laboratory. Plastic packaging and hazardous products Plastic packaging meets current requirements in terms of transport safety and content protection, including compliance with regulations on transporting hazardous substances. plastic packaging ı environment environment prevention Innovation serves reduction at source without making any concessions on required functions or altering packaging performance and user service. Research & Development supports prevention by acting on: ■ packaging weight reduction, ■ changes to shapes and volumes, ■ choice of material, ■ material mix, ■ choice of conversion process, ■ choice of graphic process. By optimising these parameters, plastic packaging plays a major role in prevention by reduction at source. 15 Plastic packaging manufacturers are constantly working on the ecodesign of their products and are active in recovery systems for packaging at the end of its lifecycle. Plastic packaging manufacturers mainly use CEN (European standardization committee) standards on the essential requirements of directive 94/62/EC. Prevention by reduction at source PAGE Qualitative prevention Plastic packaging complies with authorised heavy metal content (lead, cadmium, mercury and chrome), and with standards for environmentally hazardous substances. PAGE 16 plastic packaging ı environment Examples of prevention by reduction at source RATIO Weight 20 years ago Weight today Reduction at source % Container content > shopper bag 24 g 5.5 g - 77 % 5.5 g 10 kg > 125 g yoghurt pot 5.8 g 4.8 g -17 % 4.8 g 125 g > 1.5 L water bottle 40 g 25 g - 38 % 25 g 1.5 L > water bottle cap 3.1 g 1.8 g - 42 % > fresh vegetable bag 20 g 3.5 g - 82 % 3.5 g 5 kg 12.65 g 7.5 g - 37.5 % 7.9 g 1 kg 40 g 23 g - 40 % 23 g 300 g > drum (20 L) 1.2 kg 900 g -25 % 900 g 38 kg > EPS fish crate 100 g 87 g -13 % 87 g 3 kg > frozen vegetable bag 1000 g > ready-cooked meal tray reusable packaging and the environment In some industrial and distribution sectors, packaging that can be used several times over is a logical solution. This is especially true of reusable crates, box pallets and pallets. They are mostly made from high density polyethylene (HDPE) or polypropylene (PP). When it has gone through several rotations, reusable packaging is withdrawn from the circuit (breakage, anomalies detected, etc.) and recovered for recycling, either by packaging manufacturers who recycle it on non-food applications or by recyclers. Examples of recycling applications include industrial part transport crates, sound insulation walls and pallets. plastic packaging ı PAGE environment plastic packaging recovery The diversity of plastic packaging calls for varied processing methods for optimum recovery in both environmental and economic terms. CHOICE OF RECOVERY METHOD The following parameters have to be taken into account: > packaging location and quantity > packaging size > former contents > type of material HOUSEHOLD PACKAGING Recycling Small packaging (food, personal care, healthcare, beauty...) sorted and recycled. Energy recovery Bottles* * Provided that the polymers used are compatible with available recycling channels. Inappropriate sorting for recycling. Very low environmental gain/costhigh content residue vs. packaging size. Reusable Packaging PE and PP (crates, pallets) Industrial hollow bodies (buckets, cans, drums, containers and big bags) Recycling Two recovery methods After being used several times. When no longer suitable for use (wear, breakage). Recycling (depending on product contained in packaging). Energy recovery. Before recovery, some packaging types are reworked for reuse. EPS packaging (cushioning material, boxes) PE films (palletising covers, large sacks) Recycling Recycling The main recovery method used. Recycled if resource > 100 tons/year or if nearby recycling facilities. If not, energy recovery recommended (e.g. household EPS packaging). INDUSTRIAL AND COMMERCIAL PACKAGING 17 PAGE 18 plastic packaging ı environment RECYCLING Used collected packaging is processed to obtain a new secondary raw material. In this stage, known as regeneration, the material is prepared with precisely defined technical specifications for making new products. > concertation > anticipation > innovation In some cases, recycling can be a loop that makes packaging or creates new products in different applications. Homogenous used plastic resources result in environmentally and ecologically satisfactory recycling. Guidelines “Designing and Manufacturing Plastic Packaging for Optimum Recovery”, guide produced by CSEMP. +++++ COTREP: an ecodesign process COmité Technique de Recyclage des Emballages Plastiques COTREP (technical committee for recycling plastic packaging), provides useful help in the ecodesign of innovative plastic packaging for optimum recycling. Founder members of COTREP COTREP advises industrials with questions on the recycling feasibility of new plastic packaging, whether they are: ■ fillers ■ plastic packaging manufacturers ■ process rights holders ■ plastic producers COTREP publishes: ■ Technical notices: issued to the businesses that submit their packaging for a recycling assessment. ■ General notices: COTREP tackles problems concerning packaging or packaging components in order to examine their recycling behaviour. In this case, COTREP issues general notices that form a knowledge base available to all players in the packaging chain. All published notices are available on the COTREP website: www.cotrep.fr plastic packaging ı PAGE environment ■ The different recycling processes Raw material recycling (chemical) Physical chemical processes that decompose plastics into their initial components for use in making plastic raw materials or other products. ■ Packaging material recycling (mechanical) Physical process in which used packaging is regenerated into secondary raw material for use in manufacturing new products. To design recyclable plastic packaging: concertation – anticipation – innovation are essential through the entire chain (plastics producers, packaging manufacturers, packaging users, recyclers). Some recycling applications Material Origin HDPE (High Density Polyethylene) ■ Milk, fruit juice bottles ■ Wine boxes (5 L) ■ Washing liquid, softener LDPE (Low Density Polyethylene) ■ Films and bags and detergent bottles PP (Polypropylene) PVC (Polyvinyl Chloride) ■ Bottles: EPS (Expanded Polystyrene) ■ EPS packaging: PET (Polyethylene Terephtalate) ■ Bottles: wine, vinegar trays, crates, cushioning mineral and spring water, soft drinks, beer, wine, cider, vinegar Examples of recycling applications ■ ■ ■ ■ ■ ■ ■ New bottles Cans Cable tubes Chucks Various injected parts Bin bags Agricultural films ■ Shoe reinforcements ■ Tubes ■ Building pipes ■ ■ ■ ■ New EPS packaging Insulation panels Cushioning CD case backs and other plastic parts ■ Lightweight concrete ■ ■ ■ ■ ■ ■ ■ Padding fibre Unwoven fibre (filters, etc.) Woven or knit fibre Rigid packaging Hoops Bottles Various injected parts 19 PAGE 20 plastic packaging ı environment ENERGY RECOVERY Energy recovery applies above all to small, light, soiled plastic packaging for which sorting is technically or economically unsuited to recycling. The aim is to use combustible packaging waste to generate power by direct incineration with or without other waste, but with heat recovery. The energy thus recovered can be used for urban heating or electricity production. Every year in France, 300.000 tons of oil equivalent is saved in this way. Given the growing impact of energy costs, this is a major economic factor. If incinerator loads are well balanced and distributed (30% plastic is sufficient), incineration yield is optimal. As the excellent heat output of plastics helps the incineration of low-energy non-recyclable waste, maximum reduction of other incinerated products and lower quantities of final combustion residue, including clinker, are also observed. Plastics offer an energy gain that makes them suited to energy recovery in line with directive 94/62/EC in appropriate facilities (household or special waste). The Swedish town of Goteborg is 75% Energy recovered from the main plastics Material NCV* MJ/kg Effective energy yield** MJ/kg PE 43 22 PP 44 24 PS / PSE 40 22 PVC 17 9 PET 22 12 * Net calorific value ** After correction for material type Comparison of energy values (KJ) heated by energy recovered from household waste, including a large share of plastic. Comparison of energy values (KJ) 51 250 41 000 30 750 20 500 10 250 1 kg lignite 1 kg diesel oil 1 kg plastics plastic packaging ı environment PAGE protecting the environment on production sites Protecting the environment is a constant concern for plastic packaging manufacturers. This unceasing focus involves the use of clean technologies. More generally, it reflects environmentally responsible behaviour. The impact of industrial activity is limited by lower consumption of non-polluting energy (electricity) but also by regular efforts to recover heat (exchangers) or save water (closed circuits). Atmospheric emissions are kept within very low, controlled limits (recovery of solvents and volatile organic components under “classified facility” regulations). Active watch for the best available techniques and regular contacts with governing bodies are organised. Production waste volumes are constantly optimised. In addition, they are monitored to ensure strict waste traceability, processing and disposal. During transport, plastic packaging’s light weight means energy savings. 21 PAGE 22 plastic packaging ı environment manufacturers’ active committent Household packaging Packaging and film manufacturers that are members of CSEMP* and flexible packaging manufacturers (UNITES** members), together with plastics producers (PLASTICSEUROPE France***) financially and technically support VALORPLAST, a partner in ECO-EMBALLAGES, in managing and recovering household plastic packaging. Since 1993, VALORPLAST has managed the household plastic waste collected and sorted by local services under the ECO-EMBALLAGES programme in order to recycle it. Industrial and commercial packaging Packaging manufacturers and plastic producers have created three matching recovery channels to process their packaging, taking its specificities into account (materials, contents, resources, relevant recovery methods). They give financial and technical support to ■ ECOFUT: an association created in 1992 by industrial packaging manufacturers, in which plastics producers are involved, organises recovery of plastic drums, cans, buckets and big bags. Through its network of approved operators, ECOFUT offers manufacturers in all sectors practical solutions for recovering their packaging. ■ Eco PSE: an economic interest group founded in 1993 with the mission of promoting and organising expended polystyrene (EPS) packaging recovery channels. Its members represent 95% of EPS manufacturers who work closely with raw material producers, ESP converters and recycling professionals through a network of around 40 sites across France. ■ RECYFILM: represents the plastic film manufacturers grouped together in CSEMP, as well as recoverers and recyclers. The latter recycle various industrial films, especially pallet covers and large sacks. * CSEMP: French plastic packaging association ** UNITES: French flexible packaging association *** PLASTICSEUROPE France: French plastic producers association plastic packaging ı consumption sectors consumption sectors Closure and dispensing systems serve both the product and the user and are present in every major sector. Plastics, through the diversity of their materials, advanced technical characteristics and cutting-edge conversion processes, play a crucial role in closure and dispensing systems. Depending on the application sector, plastics deliver: ■ Convenience ■ Tamper-proofing ■ Safety ■ Watertightness ■ Accurate dosage ■ Easy opening and closing ■ Styling ■ Marketing ■ Hygiene ■ Preservation 23 A world of solutions in consumer products, B to B and distribution. > Food > Healthcare > Perfumes-cosmetics > Industry and distribution > Cleaning products Caps, pumps and valves are integral parts of many packaging solutions, whether in consumer or B to B products. PAGE Products: ■ Caps ■ Hinged caps ■ Child safety caps ■ Pour-through / service caps ■ Lids ■ Pistols ■ Pumps ■ Valves PAGE 24 plastic packaging ı consumption sectors Food industry Plastic packaging can adapt to the needs of every type of consumer and their lifestyle and habits, and to every distribution channel (supermarkets, catering, etc.). Application characteristics • Adapts to the various food distribution channels and to the high fill rates needed for fast-moving consumer goods > safety > hygiene > conveniences > conservation • Meets consumer expectations: convenient packaging, dispensing packaging, ready-to-use products, splittable products (portions or snacks), nomadic consumption (robustness and safety), fun packaging, etc. • Withstands wide temperature ranges (freezer, microwave, etc.) • Consumer information and communication vehicle through multiple printing and labelling possibilities > service • Provides for product traceability > marketing • Economical > high fill rates > technically suited to food and food packing methods > economical • Lightweight, tough, airtight, transparent, opaque, coloured, etc. plastic packaging ı consumption sectors Technical characteristics • Respects the product’s texture, smell, colour and sensory quality • Preserves through high impermeability to gases, vapour and light and UV protection • Breathable: in some cases, packaging can let oxygen in and CO2 out • Perforation- and tear-resistant • Prevents both mould growth and drying • Food products may require in-pack processing, e.g. vacuum cooking, pasteurised preparation, sterilisation, protective atmosphere filling, keeping time extension. After this kind of packed product treatment, the selected plastics keep their required properties in terms of permeability, neutrality and watertightness. For sterilisation, the packaging must remain both airtight and watertight. Plastic packaging in the food industry: a world of solutions FOOD products ■ Animal foods ■ Bread, cakes, pastries ■ Cold meats, catering products, ready-cooked meals ■ Components and ingredients (flavourings, colourings, etc.) ■ Jam, honey, toppings, chocolate powders ■ Condiments and sauces ■ Cheese ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Fruit and vegetables Ice cream ■ Eggs Fresh dairy (yoghurt, butter, etc.) Catering Take away Frozen foods Meat, poultry and seafood Mineral and spring water, sodas Oil, vinegar Fruit juice ■ Milk food PACKAGING ■ Bags ■ Barrels ■ Beakers ■ Bowls ■ Caps – Serving and dosing caps ■ Bottles ■ Boxes – Tray boxes ■ Cans ■ Containers ■ Crates, including reusable crates ■ Films – Multilayer films ■ ■ ■ ■ ■ – Stretch films Flasks ■ Jars ■ Lids Pumps ■ Sachets ■ Seals Tableware ■ Trays Tubes ■ Unitisation films Valves ■ Tubs PAGE 25 PAGE 26 plastic packaging ı consumption sectors Healthcare Health product packaging has to meet high stan dards for user safety, preservation, hygiene, packaging discretion and efficiency, therapeutic efficacy, ease of use and handling for patients or healthcare personnel and economy, etc. > innocuousness > preservation > safety > efficacy Plastic packaging can meet the strict requirements of the health sector, including accurate dosage, innocuousness, airtightness, user comfort and information security. Main application sectors Plastic packaging in health covers the pharmaceutical, medical, hospital and veterinary sectors. It corresponds to the ethical, generic and OTC health product markets. Technical characteristics • Inert with respect to contents (protection of active principle) • Airtight (tamper-proof through good weldability) • Watertight • Organoleptic • Stable • Sterilisable • Unbreakable (quality required in both hospital and domestic environments) • Meets national, European and American pharmacopoeia criteria • Flexible or rigid, according to needs Plastic packaging in healthcare: • Transparent, translucent or opaque • Lightweight a world of solutions PHARMACEUTICAL forms ■ Dry: tablets, capsules ■ Drinkable liquids: syrups, drops • Low storage bulk (stackable, optimised shapes) • Suited to single doses ■ Injectable liquids: vaccines, sera ■ Pastes: ointments healthcare PACKAGING ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Airless systems ■ Ampoules Blister packs ■ Blood bags Bottles Bottles for eye drops Boxes ■ Cans Caps for eye drops Cases - Cushioning material Feeding bottles ■ Films Flasks ■ Mini-flasks Flexible or rigid bottles ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Heat-sealed closures Inner closures ■ Jars Pill boxes ■ Pumps Rigid tubes ■ Sachets Screwcaps Single doses-units Sprays ■ Tablet dispensers Tamper-proof caps Nozzles ■ Tubes for creams Vaccine doses ■ Valves plastic packaging ı consumption sectors PAGE 27 Perfumes-cosmetics Styling, colour, feel, chemical resistance, pre ser vation, accurate dosage, a marketing vehicle: plastic packaging can meet all these crucial requirements while ensuring consumer safety. Plastic packaging can provide the general public with beauty products via every distribution channel. It has also helped to bring these products within most people’s reach. > design > marketing For maximum on-shelf standout, plastic packaging plays its role by endlessly diversifying shapes, colours and designs. Application Characteristics Technical characteristics Plastic packaging in the beauty sector can adapt to trends in cosmetic or make-up formulations, the movements used to apply them and consumers’ lifestyles. It can have an instructive role and facilitate better make-up or skincare practices. a world of solutions ■ Perfumes and perfumed lines ■ Personal care (shampoo, toothpaste, foam bath, shower gel, deodorant, etc.) ■ Hair products beauty PACKAGING ■ Airless systems ■ Bottles ■ Boxes ■ Caps ■ Capsules ■ Closures ■ Compacts ■ Cushioning material ■ Films ■ Flexible and multilayer tube components ■ Flexible tubes ■ Jars ■ Joints and seals ■ Lids ■ Brushes • Various effects through mineral fillers (e.g. glitter) that can change the packaging’s appearance or increase its density Visual and sensory characteristics BEAUTY products compacts, lipsticks, foundations, etc.) ■ Face and body care ■ Sun products • Chemical resistance (for alcoholic products, particularly in fragrances) • The flexibility of some materials provides for application by squeezing and enhances ease of use Plastic packaging in perfumes & cosmetics: ■ Make-up (mascara, • Resistance to impact and scratching ■ Mascaras ■ Nozzles ■ Overcaps ■ Protective covers ■ Pumps ■ Reinforcing bands ■ Rigid tubes – Lipstick tubes ■ Sample sachets ■ Sticks ■ Tottles ■ Tubes ■ Transport trays ■ Valves • Colour, transparency (opalescence, translucence, etc.) • Shape • Look and feel (gloss, matt, satin, etc.): some materials reproduce the appearance of skin, fabric or stone and give a distinctive tactile sensation (e.g. soft touch) or soft, silky or pearlized surfaces PAGE 28 plastic packaging ı consumption sectors Industry and distribution LOGISTICAL PACKAGING > logistics > handling > reutilisation > robustness > ergonomics Main consumption sectors • Food • Industry • Automotive • Pharmaceuticals & Cosmetics • Healthcare • Transport, etc. Packaging • Crates • Box pallets • Pallets • Pallet dividers Technical characteristics • The packaging’s robustness ensures the product carried remains intact and is not squashed. • Simultaneously, the packaging’s light weight provides ergonomics (handles, no sharp edges), convenience and ease of handling, but also impact and stacking resistance, constant tare weight and hygrostability. RIGID INDUSTRIAL PACKAGING (Hollow bodies) > safety > ergonomics > handling > chemical compatibility Main consumption sectors • Chemicals • Petrochemicals • Parachemistry • Building and Public Works • Agriculture • Food • Other industrial sectors (Automotive, etc.) Packaging • Cans • Drums • Bulk containers • Buckets, etc. • Designed to ensure optimum washing and drying conditions (avoiding water retention zones and holes, etc.). Plastic’s very nature (smoothness, etc.) makes it easy to clean. • Transport savings • Openwork: ventilation (facilitates product preservation in cold chain, etc.) • European standard formats • Traceability, etc. Application characteristics Reusable plastic packaging combines storage and logistical functions. Some packaging types are also used for product presentation at point of sale. These products deliver benefits to users and lead to productivity gains as part of a logistics organisation. In addition, they make rational, highly attractive shelf organisation possible. plastic packaging ı consumption sectors Benefits PAGE Technical characteristics • Safety • Security • Safe transport • Ergonomics • Design • Optimised shapes to carry maximum quantity with minimum bulk • Standardisation • Hygiene • Permeability • Watertightness • Emptying • Handling (grips suited to volume and weight of contents) • Handles help to avoid liquid retention during emptying • Physical strength • Chemical compatibility • Transport of hazardous substances • UN markings • Barrier properties (permeability) • Opening and closing • Sealing / Capsuling • Labelling of hazardous products • Antistatic properties FILM > lightness > efficiency > reliability > service INDUSTRIAL SECTOR Film is used in every industrial and distribution centre. Its main characteristics are low thickness and bulk and very low weight for packing and transporting heavy loads. Main consumption sectors • Industry • Agriculture • Construction • Distribution, etc. Packaging • Sacks for industrial products (fertilizer, plaster, cement) • Bubble films • Pallet films • Stretch films (used to group products together and attach loads to a pallet) • Shrink film (on pallets) Waste bags: used by hospitals, building sites (rubble), local services Characteristics • Low thickness • High strength-to-weight ratio • UV resistance • Protection from scratches during transport • Wedging (bubble film) • Tamper protection • Quick product identification (printed, transparent) • Water-resistant • Low bulk • Stretchable • Shrinkable MASS RETAIL SECTOR Packaging • Waste bags: in mass retailing and cash & carry • Pack division (liquids, food cans, etc.) • Bagging: checkout bags, fruit & vegetables, promotional bags • Film for food use • Film for personal care products BIG BAGS > robustness > lightness > safety Big bags are flexible packaging used to pack and transport solid products in various forms. Main consumption sectors • Industry (chemicals, food, etc.) • Agriculture • Construction, etc. Characteristics • Easy storage, emptying and handling • Technical performance tested in approved laboratories, i.e. fatigue, fall, overturning, pick-up, compression/ stacking and UV resistance tests on sheets. 29 PAGE 30 plastic packaging ı consumption sectors Cleaning products Whether used in homes, industry, retailing or agriculture, plastic is the main packaging material for cleaning products. Plastic packaging delivers safety, convenience, ergonomics and ease of use. Characteristics > dosage > ergonomics > safety • Reliability, convenience and product enhancement • Easy handling: packaging with handles • Secure closure systems: dispenser caps, pour-through stoppers, pistols, child safety • Product protection, particularly for hazardous substances • Vast choice of original shapes • Transparency or opacity, colour Main consumption sectors • Household • DIY • Gardening • Agriculture/Livestock • Industry • Distribution Packaging • Bottles • Cans • Eco-refills • Drums • Jars • Buckets • Containers • Bags • Sachets • Weight reduction: with the growth of concentrated products, containers have got smaller. Plastic bottles are particularly suited to trends, size changes and optimised shapes. • Adapted to logistics and shelf-stacking • Traceability • Economical, with the value for money required in mass retailing plastic packaging ı PAGE CSEMP the French Plastic Packaging Association The voice of the plastic packaging and film industry. An essential collective factor in businesses’ individual performance. With and for manufacturers in the sector, CSEMP acts on the environment to influence events, protect the image of plastic packaging and film, represent the trade with public and corporate bodies, communicate and provide and interface with key partners. Relations with members Commissions handle sector-wide issues; sections and workgroups focus on specific and technical areas. Information is given via an extranet and restricted to members. With around a hundred member companies, CSEMP represents 70-90% of the market depending on the packaging and film sector. Main work orientations > environment > European (CEN TC 261) and French standardisation CSEMP is a member of: ■ Fédération de la Plasturgie (French plastics federation for converters ■ CLIFE (French packaging industries liaison committee) Conseil National de l’Emballage (National packaging council) EuPC (European Plastic Converters Association) CETIE (International technical centre for bottling and related packaging). > Europe > communication > industrial relations > materials in contact with food - hygiene > transport of hazardous substances ■ ■ ■ For the management of household, industrial and commercial packaging waste, the manufacturers that belong to CSEMP are active in Valorplast, ECOFUT, Eco PSE and Recyfilm. 31 PAGE 32 plastic packaging ı CSEMP PLASTIC PACKAGING AND FILM MANUFACTURERS ■ AGRIPLAS (ROULLIER) ■ AIRSEC (SUD CHEMIE) ■ ALCAN PACKAGING BEAUTY ■ ALLIBERT BUCKHORN ■ ALPLAST Groupe ■ AMCOR PET PACKAGING ■ ARGOAT PLASTIQUES ■ AURIPLAST (QUALIPAC) ■ AUTOBAR PACKAGING FRANCE ■ AUTOBAR FLEXIBLE DECORATIVE PACKAGING ■ AUTOBAR FLEXIBLE PACKAGING PREMIUM ■ AXILONE PLASTIQUE (ILEOS) ■ BARBIER Groupe ■ BERICAP FRANCE ■ BOURBON PLASTIQUES ■ CASTELLETA ■ CGP FILM ■ COEXPAN FRANCE ■ COFRESCO ■ COLLY & MARTIN ■ DECOMATIC ■ DOW ■ EUROPLASTIQUES ■ EXAPLAST ■ GERRESHEIMER PHARMA PLASTIC SYSTEM ■ GIZEH EMBALLAGE ■ GLOBAL CLOSURE SYSTEMS ■ GREIF ■ GUILLIN EMBALLAGES ■ HUHTAMAKI FRANCE ■ INCOPLAS FRANCE ■ ISOBOX (SYNBRA) ■ JOKEY FRANCE ■ KNAUF ■ LEYGATECH ■ LINPAC MATERIALS HANDLING FRANCE ■ LISI COSMETICS ■ LMA PACKAGING (QUALIPAC) ■ LM PLASTIQUES ■ LOGOPLASTE FRANCE ■ MALIP ■ MAUSER EMBALLAGES ■ MEADWESTVACO CALMAR ■ MILLET MARIUS ■ MOB (SMOBY) ■ NMBP ■ NORMANPLAST (TOTAL) ■ NOVEMBAL TETRA PAK CLOSURES ■ ONO PACKAGING ■ PANSAC ■ PLASTIKPACK FRANCE ■ PLASTOBREIZ ■ PLASTUNI ■ POLIMOON ■ POUB’SAC ■ QUALIFORM (QUALIPAC) ■ QUALIPAC (POCHET / ALLIBERT) ■ REXAM PLASTIC PACKAGING ■ REXAM DISPENSING SYSTEMS ■ RPC BEAUTE ■ SAINT-ANDRE PLASTIQUE ■ SAINT GOBAIN VG EMBALLAGE ■ SCHOELLER ARCA SYSTEMS ■ SCHUTZ FRANCE ■ SICAL (ROSSMANN) ■ SIDEL ■ SINCOPLAS ■ SIRAP GEMA FRANCE ■ SOLOCAP ■ SOMATER CONDI TION NEMENTS ■ SOPAVE ■ SOTRALENTZ PACKAGING ■ SPHERE ■ STED FLACONNAGE (STARD) ■ STOROPACK ■ SUPERFOS BESANCON ■ SUPERFOS INDUSTRIE ■ TEXEN ■ TIAG INDUSTRIES ■ TOP EMBALLAGE / RIEKE PACKAGING SYSTEMS ■ TOURNAIRE ■ TRANSIT (PLASTIC OMNIUM) ■ VALOIS (APTAR) ■ VITEMBAL ■ WERIT. RECYCLERS ■ AMCOR PET RECYCLING ■ APPROVAL 87 ■ COMPTOIR DES PLASTIQUES DE L’AIN ■ ECHALIER ■ FREUNDENBERG POLITEX ■ ICO POLYMERS FRANCE ■ MATIERES PLASTIQUES DE BOURGOGNE ■ REGENE ATLANTIQUE ■ SOREPLA (ENVIPCO) ■ SRV VACHER ■ TERGAL FIBRES ■ WELLMAN FRANCE RECYCLAGE. LOGISTICIANS ■ CHEP FRANCE ■ EURO POOL SYSTEM. USEFUL contacts > CONSEIL NATIONAL DE L’EMBALLAGE [email protected] www.conseil-emballage.org Phone: 33 (0)1 46 37 16 00 > COTREP www.cotrep.fr > ECO-EMBALLAGES [email protected] www.ecoemballages.fr Phone: 33 (0)1 40 89 99 99 > ECOFUT [email protected] www.ecofut.org Phone: 33 (0)1 46 22 02 23 > Eco PSE [email protected] www.ecopse.fr Phone: 33 (0)1 46 53 11 34 > Fédération de la Plasturgie [email protected] www.laplasturgie.fr Phone: 33 (0)1 44 01 16 16 > PlasticsEurope France [email protected] www.lesplastiques.com Phone: 33 (0)1 46 53 10 53 > RECYFILM [email protected] www.packplast.org Phone: 33 (0)1 46 22 33 66 > UNITES [email protected] www.unites-fr.org Phone: 33 (0)1 46 22 09 09 > VALORPLAST [email protected] www.valorplast.com Phone: 33 (0)1 46 53 10 95 PHOTO credits Alcan Packaging Beauty ■ Allibert Buckhorn ■ Antoine for CSEMP ■ Atofina ■ Atofina-G. Gauchet ■ Autobar Packaging France ■ Autobar Flexible Decorative Packaging ■ Barbier Group ■ Bericap France ■ Cabot ■ CSEMP ■ Philippe Cluzeau for Valorplast ■ D&J ■ DigitalVision ■ Europlastiques ■ Euro Pool System ■ Fédération de la Plasturgie ■ John Foxx ■ Guillin Emballages ■ Global Closure Systems ■ Huhtamaki France ■ Jokey France ■ Knauf ■ Lisi Cosmetics ■ Lucas for Rouge Vif ■ Lustucru ■ Mauser Emballages ■ Mob ■ Nocibé ■ Normanplast ■ Origine ■ PhotoAlto-Pierre Bourrier ■ PhotoAltoMichel Bussy ■ Polimoon ■ PSA ■ Rexam ■ Rouge Vif ■ Rubberball Productions ■ Saint-Gobain VG Emballage ■ Schütz France ■ Somater Conditionnements ■ Sphere ■ Stockbyte Platinum ■ Stockbyte Silver ■ Superfos ■ Valois ■ Valorplast. Plastic packaging is with us in our daily lives, protecting the environment French Plastic Packaging Association 5, rue de Chazelles 75017 Paris - France - Phone: 33 (0)1 46 22 33 66 - Fax: 33 (0)1 46 22 02 35 [email protected] - www.packplast.org ROUGE VIF RCS VERSAILLES B 345 174 221 - APRIL 2007 and helping to keep us safe.
