life cycle assessment and packaging - tappi · life cycle assessment and packaging director, us -...

Life Cycle Assessment and PackagingDirector, US - [email protected]

OlivierJolliet

Jon Dettling

Co-founder – QuantisProfessor – Univ. of Michigan

[email protected]

Life Cycle Assessment and Packaging

•Why LCA?: case study with polystyrene peanuts

Packaging sustainability measurement and LCA:•What’s the function?

•What packaging to consider?•Industry guidance

•LCA and design•LCA and communication•The packaging context: end-of-life considerations

Why LCA?Why LCA? FunctionFunction What Pkg?What Pkg? DesignDesign EoLEoLCommunicateCommunicateIntro.

What’s Really “Green?”• An increasing number of claims:

• 100% Recycled• Recyclable• Energy Efficient• Organic• XYZ-Free• Reduced packaging• Bio-based• “Greener!”

• How do we make sense of this?• We need a system to weigh all the

competing factors.

3

Why LCA?Why LCA? FunctionFunction What Pkg?What Pkg? DesignDesign EoLEoLCommunicateCommunicateIntro.

Case Study: Packing with Popcorn?

Example LCA of packaging material:Polystyrene and Corn Popcorn

How can we know which is really a better environmental choice? How do we measure this?

What are the key factors to consider?

How can we know which is really a better environmental choice? How do we measure this?

What are the key factors to consider?

FunctionFunction What Pkg?What Pkg? DesignDesign EoLEoLCommunicateCommunicateIntro.Intro. Why LCA?

Polystyrene: Non-renewable and non-biodegradable materialPolystyrene: Non-renewable and non-biodegradable material

What about real pop-corn? Renewable and biodegradable

What about real pop-corn? Renewable and biodegradable

6

Comprehensive evaluation of the environmental and human health impacts of a product,

process, or service

Comprehensive evaluation of the environmental and human health impacts of a product,

process, or service

LCA is the only internationally accepted

method for substantiating a claim or decision that one

product, service or technology is

environmentally preferable to another.

(ISO 14040 series)

Defining LCA


LCA phases and process

Definition of objectives &

system

Definition of objectives &

system

Inventory of resources & emissions

Inventory of resources & emissions

Impact Assessment

Impact Assessment

InterpretationInterpretation

Application

•Product development•Product improvement

•Strategic planning•Marketing

•Public policy-making

Application

•Product development•Product improvement

•Strategic planning•Marketing

•Public policy-making


Renewable packing materials:system boundaries


www.quantis-intl.com

Advantage of LCA:See the whole picture

Emissions displaced, Emissions displaced, not eliminatednot eliminated

LCA prevents

burden-shifting

LCA prevents

burden-shifting

� From one life cycle stage to

another

� From one region to another

� From one compartment

(water, air, ground) to another

� From one impact to another ...

� From one life cycle stage to

another

� From one region to another

� From one compartment

(water, air, ground) to another

� From one impact to another ...


Resources ResourcesResourcesResources

Emissions EmissionsEmissions Emissions

LCA Inventory


Life Cycle Inventory Results

Emissions Popcorn

g/kg Polystyrene

g/kg Air CO2 620 5480 Particles 0.2 1.3 CO 1.0 3.4 NH3 3.1 0.0 Water Nitrates 31 0.0 Extractions MJ/kg MJ/kg Energy non renouv. 7.2 81.3


Which is better?

LCA Impact Assessment:Midpoint and Endpoint

e.g. IMPACT 2002+

Int J LCA 8 (6), 324-330Int J LCA 9 (6), 394-404


Popcorn impacts compared to Polystyrene impacts

per kg materials

Ecopoints Critical volumina Critical surface-time

0%

20%

40%

60%

80%

100%

PS

PC

PS

PC

PS

PC

Phosphates

Nitrates

NH3

SO2

NOx

HC

CO

Part.

N2O

CO2

per kg materials


0%

20%

40%

60%

80%

100%

PS

PC

PS

PC

PS

PC

Phosphates

Nitrates

NH3

SO2

NOx

HC

CO

Part.

N2O

CO2


Popcorn is clearly the better choice for the environment

Popcorn is clearly the better choice for the environment

?

Is this the right comparison to make?

• Is a comparison per kilogramrelevant?

• What is the packing trying to achieve? Adding mass?

• We need to define a “functional unit”, which gives us a proper basis for comparison

1

4

per kg materials


0%

20%

40%

60%

80%

100%

PS

PC

PS

PC

PS

PC

Phosphates

Nitrates

NH3

SO2

NOx

HC

CO

Part.

N2O

CO2

per kg materials


0%

20%

40%

60%

80%

100%

PS

PC

PS

PC

PS

PC

Phosphates

Nitrates

NH3

SO2

NOx

HC

CO

Part.

N2O

CO2

• To be effective, packing material must take up space and have properties to cushion against movement

• So our comparison is more relevant based on volume rather than mass


Popcorn impact compared to polystyrene impacts

0%

50%

100%

150%

200%

PS

PC

PS

PC

PS

PC

Phosphates

Nitrates

NH3

SO2

NOx

HC

CO

Part.

N2O

CO2

per m 3 materials


0%

50%

100%

150%

200%

PS

PC

PS

PC

PS

PC

Phosphates

Nitrates

NH3

SO2

NOx

HC

CO

Part.

N2O

CO2

per m 3 materials



By volume, polystyrene is the better choice for the environment

By volume, polystyrene is the better choice for the environment

Conclusions:Popcorn vs Polystyrene

• “Natural” is different from “environmentally friendly”

• Must consider whole life cycle and range of environmental impacts

• Impact assessment allows interpretation of results

• Key parameters from an environmental point of view : density, number of reuse

• Material function or service is essential


LCA of Hand Drying Alternatives

1

7


LCA and Packaging

What is the Function of Packaging?

• To protect the product and deliver it to its site of use- It is therefore linked to the product amount /

function- If product is lost, more packaging and product must

be produced to replace the function- It is therefore necessary to consider the product’s

life cycle when the rate of product lost might be altered

• Packaging can also have other functions (e.g. to act as a drinking container)

What Pkg?What Pkg? DesignDesign EoLEoLCommunicateCommunicateIntro.Intro. Why LCA?Why LCA? Function

Indirect impacts of packaging on product may matter: toothpaste

0

1

2

3

4

5

6

7

8

9

10

Standard tube +carboard

Self standingtube

Dosing tube

Ene

rgy

(MJ)

Toothpaste Packing Toothpaste wastes

Impact of wasted toothpaste is significant, but not enough to

offset the benefit of new package

Impact of wasted toothpaste is significant, but not enough to

offset the benefit of new package

What Pkg?What Pkg? DesignDesign EoLEoLCommunicateCommunicateIntro.Intro. Why LCA?Why LCA? Function

Which Packaging to Consider?

2

1

Primary Packaging

Switch

Primary Packaging

Switch

Causes Secondary Packaging

Switch

Causes Secondary Packaging

Switch

DesignDesign EoLEoLCommunicateCommunicateIntro.Intro. Why LCA?Why LCA? FunctionFunction What Pkg?

CO2 Emissions at different Life Cycle Stages

0

1

2

3

4

R&D

(energy)

Raw

materials

Energy

production

Transport

Site

production

Packaging

Waste

inceneration

Buildings

kg CO2/kg product Sales representants

Business travel

Products

Employees

Raw materials

Electricity

Fossil fuel

Secondary packaging 6 x the product mass

70 x the active substance mass

Secondary packaging 6 x the product mass

70 x the active substance mass

CO2 Emissions at different life cycle stagesPharma Industry

CO2 Emissions at different life cycle stagesCO2 Emissions at different life cycle stagesPharma IndustryPharma Industry


Which Packaging to Consider?

Life Cycle Boundary:Are you seeing the whole picture?

0

1

2

3

4

R&D

(energy)

Raw

materials

Energy

production

Transport

Site

production

Packaging

Waste

inceneration

Buildings

kg CO2/kg product

Sales reps

Business travel

Products

Employees

Raw materials

Electricity

Fossil fuel


CO2 Emissions at different life cycle stagesPharma Industry

CO2 Emissions at different life cycle stagesCO2 Emissions at different life cycle stagesPharma IndustryPharma Industry

What do we measure, is there industry guidance?• The Global CEO Forum has convened a “Global Packaging Project” in

2009-2010 with a focus on establishing common sustainability metrics for packaging

• Based heavily on Sustainable Packaging Coalition’s metrics, with heavier emphasis on LCA for environment

• Process now in a pilot phase with 18 value-chain pilots now underway• Final output from the process planned for later in 2010

• Wal-Mart’s Scorecard and Sustainability Consortium will also continue to set industry-wide focus

2

4


Package design:Where do we focus?

Choice of materials

?

Supply chain

operations?

Impact of logistics

?

Material weight

?Packaging?

Form and features

?

End-of-life Management

?

EoLEoLCommunicateCommunicateIntro.Intro. Why LCA?Why LCA? FunctionFunction What Pkg?What Pkg? Design

26

Where Should We Focus our Design and R&D?


2

7

Idea & concept filtration w/ LCACriteria:•Cost •Performance•Environment

LCA can

evaluate

candidate

performance

LCA can

evaluate

candidate

performance

LCA identifies best areas for action, DfE tools offer improvement

guidance

LCA identifies best areas for action, DfE tools offer improvement

guidance

LCA supports communication on benefits of

winning design

LCA supports communication on benefits of

winning design

LCA scenario simulations to help

optimize design details

LCA scenario simulations to help

optimize design details

LCA Informs creation of candidates and

best strategies

LCA Informs creation of candidates and

best strategies


Communication Example: NatureNes Baby Food

• Nestlé develops new baby food for European market• Includes:

• freshest ingredients • new steam processing and preservation technology

2

8

There is a desire to communicate on environmental benefits of new packaging (switched from glass):

2

8

Unique Steam Cooking Process

Unique Steam Cooking Process

Simple Natural Recipes

Simple Natural Recipes

“Respect the environment:

Packaging reduces use of energy and emissions of CO2”

“Respect the environment:

Packaging reduces use of energy and emissions of CO2”

EoLEoLIntro.Intro. Why LCA?Why LCA? FunctionFunction What Pkg?What Pkg? DesignDesign Communicate

The NaturNes Case Study

2

9

Glass Jar components

Paper Label

White glass Jar

Steel PT CapPT = Press and Twist(Electrolytical tin plate, ETP)

Cardboard Cluster(to group 2 jars, optional)

Cardboard Tray(to group 3 clustersor 6 non-clustered jars)

Plastic Pot components

Plastic (PP) Pot

2 pieces of PP label

Plastic (PP) Cap

(Inside) Lidding film(PET-SiOx-OPA-PP Lid)

Cardboard Tray(to group X clusters*)

Cardboard Hood(covering the Tray)

* The number "X" of clusters per tray varies according to size and market

Cardboard Cluster(to group 2 pots)


Plastic pot system used more efficient UHT stream process

Plastic pot system used more efficient UHT stream process

Plastic pot system with current logistics has longer transport distances

Plastic pot system with current logistics has longer transport distances

Main Contributors to Global Warming:Packaging Material and Distribution

3

0

……………………………………………………

Plastic has lesser impacts to produce (for weight in package)

With “optimized”logistics network, the plastic would have an even greater advantage


How can we communicate this?

Labeling: “Reduces Energy Use and CO2”Labeling: “Reduces

Energy Use and CO2”3

1

Use phase

0 gRecycling of PP

Collection/transport20 km

8.7 g PP+EVOH

0% recycled as plastic mixture75% substituting fuel or

reducing agent in cement / steel industry

25% incinerationin MWTP

- 0gVirgin PPproduction

Figures given here are only valid for 200g plastic pots sold in Germany

-5.98 g Light fuel oil

at regional storage

Boundary Expansion

- 4.17 WhElectricity

EU mix

6.51 gPlastic shredding and preparation

2.19 gIncineration of PP in

municipal waste

Avoidedburden

Collection/Transport20 km

Collection/Transport20 km

- 29.9 kJHeat, light

fuel oil

Elec: 13% LHV Heat: 26% LHV

Functional unit1 child meal

packed & delivered

+ 3.08 Wh + 21.8 kJ- 3.08 Wh - 21.8 kJelectricity heat

+ 254 kJ- 254 kJ

for cement/ steel production

0 MJ

Spanish scenariosBaseline (green + red): 1010 kmExpected (blue + red): 2083 kmOptimised plastic (green + red): 1010 km Epinal

Sevares1570 km

System modelPlastic Pots (simplified)

Distribution

PP-EVOH-PP sheets on reels

SiOx Lidding film on reels

Thermoforming

Filling and sealing

Plastic caps

Baby food

Cap / Pot Labels on tracer

ClustersTrays and

Hoods

Capping, labelling and clustering

Trsp Packaging, coding

LDPE film (Pallets)

Steam

Raw material extraction, production, transports

Pots ready on pallet

(Use)

UHT process

Electricity

Wastes

Incineration RecyclingLandfilling

Food Container Production

Container Assembly

Distribution End of Life

*

*

***

*

Comparison on Terrestrial Acidification/Nutrification (one 200g jar or pot)

-0.001

0

0.001

0.002

0.003

0.004

0.005

0.006

0.007

0.008

0.009

Glass jars,200g, DE

Plastic pots,200g, DE

Plastic pots,200g, DE

OPT

Glass jars,200g, ES

Plastic pots,200g, ES

Plastic pots,200g, ES

OPT

Glass jars,200g, FR

Glass jars,200g, FR

OPT

Plastic pots,200g, FR

kg S

O2

Distribution (Food)

Distribution (Packaging)

On site Energy

Other

Waste Treatment

Waste Collection

Tray and Hood

Stretch Film

Lid

Label

Cluster

On site Water

Cap

Pot or Jar

Before Supplier Transports

Recycling and Heat RecoveryGermany Spain France

Review Panel, ISO 14040

Review Panel, ISO 14040

DevelopmentDevelopment LCALCA

Scientific PublicationScientific

Publication


What is the geography and context of the packaging? • Consumer behavior and public policy can

influence environmental performance

• A packaging that is “environmentally friendly in one country may not be in another• Consumers may recycle at very different rates• Infrastructure may not exist to handle recycled materials

in some locations• Policies effect rates of recycling and incineration vs.

landfill

CommunicateCommunicateIntro.Intro. Why LCA?Why LCA? FunctionFunction What Pkg?What Pkg? DesignDesign EoL

Avoided mtrl Avoided heat

Avoided electr.

Tot. energy

GWP

Plastic replacing virgin material Plastic virgin plastic biofuel or

fossils biofuel or fossil

R R

Plastic replacing other materials Plastic wood biofuel or

fossils

- I I

Paper/cardboard replacing cardboard vs biofuels Paper wood biofuel biofuels R R

Paper/cardboard replacing fossil heat or electricit y Paper wood fossil fossil I I

Adapted from Anna Björklund & Göran Finnveden


Is it better to recycle or recover energy?

Whether to recycle can depend on

what is replaced

Whether to recycle can depend on

what is replaced

Whether to recovery

energy can depend on the

alternate fuel

Whether to recovery

energy can depend on the

alternate fuel

Example: California’s beverage container recovery program

• A successful program has greatly boosted rates of recovery?

• But what do we do with the containers?• What end-markets should be developed

to provide most environmental benefit?• These end-markets will also determine

which packaging options perform best within California

3

4


Summary of Key Points:

• To judge environmental performance, we must take a life cycle perspective- Categorical information like “recycled” or “bio-based” is not sufficient

• LCA gives a credible and scientific basis to environmental decisions and claims

• Packaging LCAs must consider the function of packaging and perhaps of the product

• The full packaging system should be considered• Industry standard and coordination are emerging• LCA can help guide development of better packaging solutions• LCA can provide credibility to a marketing claim• The context can be as important as the packaging

CommunicateCommunicateIntro.Intro. Why LCA?Why LCA? FunctionFunction What Pkg?What Pkg? DesignDesign EoLEoL

Questions?

Jon Dettling

Director

Quantis [email protected]

Olivier Jolliet

Co-founder, Quantis

Professor, Univ. of [email protected]

life cycle assessment and packaging - tappi · life cycle assessment and packaging director, us -...

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