present state packaging

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Packaging in the U.S.

Packaging Supply ChainThe Packaging Lifecycle

IV

P RESENT S TATE OF P ACKAGING


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PACKAGING IN THE U.S.(2006)Municipal Solid Waste (MSW) Generation, with Recycling

(2006)

3 2% of the weight

& 50% of thevolume of MSWis containers andpackaging

The amount of containers andpackagingconsumedequates to 3 00pounds per

American peryear.

3 0% of all non-energy resourcesare consumed for

packaging


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P RODUCT S UPPLY CHAIN (I NCLUDING P ACKAGING )

Distribution ConsumerProductManufacturing

Component 1 of Product

Manufacturing

Raw Material 1

Raw Material i

Component n of Product

Manufacturing

Raw Material 1

Raw Material j

PackagingComponent 1

Raw Material 1

Raw Material k

PackagingComponent m

Raw Material 1

Raw Material l

Packaging TypesPrimary Packaging

Consumer PackagingS econdary Packaging

G rouping Primary Packaging Together (Cases)

Tertiary PackagingTransport/Distribution Packaging - Palletized

Process

Material

Examples

Transportation


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P ACKAGING S UPPLY CHAIN

PackagingManufacturing

ProductManufacturing

Distribution ConsumerRaw Materials

Repair

Refurbish

S ervice

Recycling

Remanufacturing

PackagingMaterials

Disassembly

Disposal

Inspection/ Sorting

End of Life Unused Packaging

U s e d P a c k a g i n g


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The Packaging Lifecycle

Recycle

Reuse or Return

Compost

Disposal to Land,Water or Air

EOLExtractionMining &Harvesting

ProductRequirements

NaturalResources

Retail

Use &Maintenance

Manufacturing(Production &

Assembly)

MaterialsProduction &Supplier Ops

T ransportation,Handling & Storage

Design

InputsFixtures, Tools &EquipmentConsumables (EnergyRaw Materials,Chemical etc.)

OutputsWaste

Filling &

Distribution


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Cu rrent State of the Packaging Lifecycle

Recycle

Reuse or Return

Compost


EOLExtractionMining &Harvesting

ProductRequirements

NaturalResources

Retail

Use &Maintenance


Assembly)



Design


OutputsWaste

Filling &Distribution

The contemporary state of packaging primarily consists of linear processes. In addition to thepackaging product, common o u tp u ts incl ud e energy an d material waste . There are few circularpaths associated with reuse of inputs. Although the quantity of wasted inputs and reuse varies,

depending on the types of materials, technology, and processes used, the outputs of the packagingmanufacturing process often have undesirable impacts on the surrounding environment.

Underutilized

Many HarmfulInputs &Emissions

Underutilized

Many Harmful

Inputs &Emissions

Many HarmfulEmissions

Many Harmful Inputs


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Plastics PackagingPackaging Supply ChainPlastics Packaging: Strengths & Weaknesses

Plastic Packaging: Advantages & DisadvantagesCurrent State of the Plastic Packaging LifecycleCase Study: Stonyfield Farms Look at Packaging

VP RESENT S TATE OF P LASTIC

P ACKAGING AND M ANUFACTURING


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P LASTIC P ACKAGING Plastics were used in thepackaging of 53 % of allgoods , comprising 20% of all

packaging by weightPlastic packagingproduction uses 270 milliontons of oil and gas

P lastic P ackaging Discarded 2006(in thousands of tons)

Plastic packaging waste hasgrown 5x faster by weightthan the plastics recycled

recycled plastics save 2- 3 pounds of greenhouse gasesfor every pound of virginplastic that they replace

Efforts to recycle plastics arehindered by difficulties, suchas:

Packaging is oftencomposed of mixed resins

Plastics have a high

volume-to-weight ratioEnd markets for recycledplastics are lacking

Recycling of mixedplastics involves a 20-step energy-intensiveprocess to sort the nearly40 different types


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P LASTICS U SEDIN P ACKAGING

Six resins account for nearlyall of the plastics used inpackaging


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if plastic packaging didnot exist, the annualextra burden required toreplace the packagingfunction would consumean additional 14.2millions tons of oil

(equal to a line of super

tanker ships over 14miles long) and producean additional 47.3million tons of CO 2(equal to the annualoutput of over 12 million

automobiles)

The Contribution of Plastics Products toResource Efficiency, Gesellschaft fur umfassende Analysen, 2005 (PlasticsEurope)

C osts - generally less than alternatives

Little material req u ires packaging uses less than comparableitems made from other sources

Lightweight - resulting in reduced cost/fuel/emissions of transport

Strength less material requiredM ol d able package can be custom made, cutting down on fillerpackagingD u rable resistance to corrosion

Sanitary keeps products sterile and free of contamination;tampering is evident

Impermeability to moisture, chemicals, infestation, and airR etains liq u i d s, freshness, an d flavor prevents spoilage andcan be made resealableT emperat u re retention and can be subjected to a wide range (canbe frozen & microwaved)

Safety fewer injuries from breaking, shattering, leaking,tampering, child-resistanceA esthetics :

y Color can be easily variedy Transparent especially important for medical purposes

R e u sableR ecyclable &/or protects other packaging to increases recyclability

P LASTIC P ACKAGING : S TRENGTHS


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In the central Pacificgyre, the AMRF[Algalita Marine

Research Foundation]in 2002 found 6 kilosof plastic for everykilo of plankton nearthe surface.

Marine litter canhave a seriousnegative impact oncoral reef ecosystems.In particular, plasticitems, incl ud ingsheeting an d bags,may cover reefs,blocking off thes u nlight an d oxygenthat polyps nee d tos u rvive .

[UNEP/Regional Seas and the

GPA.. p 4 &16 ]

N egative Image of their EOL environmental impacts, and the social,economic and environmental issues entrenched in source of the materials(though the petroleum industry)T oxicity- concerns have prompted publish of guides on what plastics toavoid

P LASTIC P ACKAGING : W EAKNESSESIt is the very properties that make plastics so useful, their stabilityand resistance to degradation, that causes them to be so problematicafter they have served their purpose. These materials persist in the

environment and are not readily degraded or processed by naturalbiological mechanisms. [Allsopp et. al. , p 4]

Lifetime & D egra d ability plastics take many years to breakdown, andeven when they do degrade, they do not biodegrade, causing concern aboutthe particles impact on the environment.F loatation- many types of plastics float and thus can be more easilydistributed to large tracks of ocean, unlike other types of debris whichsink.

Lack of R ecycling Infrastr u ct u re hinders reuse. Although plasticsmay have to be recycled separately, often they look the same and thiscauses confusion among consumers.V isibility , both in the trash bin and in the environment, supports the

urban tumbleweed image and promotes plastic as an emblem of athrowaway society.


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A d vantages

Manufacturingy Relatively low water usey Easy to create a composite package with

co-extrusion and laminationUse

y Inexpensivey Versatile use because the material is inert,

strong (for weight), durable, will not leachchemicals, usable at high temperatures, a

good barrier for moisture and gasy Transportation GHG emissions reduced

because of weightEOL

y Ability to use lots of recycled material andloose little structural integrity (high storedenergy)

y Quick sterilizationImplementation

y Existing recycling and some reuseinfrastructure

D isa d vantages

Sourcey Non-renewable resources

Usey Toxicity concerns regarding the use of styrene

compounds on human health (when used infood containers etc).

EOLy Reuse -Occasionaly Recycling - Not for mixed plastics (including

popular composites) mainly PET & HDPEy Not biodegradable (harm on ocean life has

been recorded from plastic materials)Implementation

y Contemporary recycling infrastructure isincomplete and not widespread

y Hard to tell resins apart

Plastic Packaging


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MissingFeedback

Loops

Recycle

CompostEOL

ExtractionMining &Harvesting

Retail

Use &Maintenance


Assembly)



Design


OutputsWaste

Filling &

Distribution

Many

Outputs& ToxicityConcerns

ManyInputs

P LASTICS Current State of the Packaging Lifecycle

ProductRequirements

SomeCrucialUses

Customizable, but requiresmany Inputs

& Outputs

Reuse or Return


NaturalResources


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C ASE S TUDY :Stonyfiel d F arms Packaging C hoices

Use of resin code #5 plastic (fewrecycling facilities), but allows materialreduction

Tellus Institute found:y Over 95% of the environmental cost

is in the production of the package-

in the energy used and toxinscreated in the manufacturingprocess.

y the lightest-weight package,per u nit of d elivere d en d pro du ct, is generally the lowest-impact pro du ct

The University of Michigans LCA on Stonyfield Farms productdelivery system concluded:

y container size ha d greater impact than the c u psman u fact u ring process or its material (ie. Largest packageclear winner in waste creation and energy consumption)

y 1/3 of life cycle total energy consumed was during the materialproduction phase and distribution to distributors and retailers


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University of MichigansRecommendations:y Educate consumers

regarding the effect thatcontainer size has onenvironmental burdens.

y

Improve performance relatedto product transport anddistribution.

y Optimize the mix of primaryand secondary packaging forenvironmental performance.

y

Evaluate alternative primarypackaging materials andconfigurations.

y Analyze impact of usingmore efficient or lowerimpact manufacturingprocesses.

C ASE S TUDY :Stonyfiel d F arms Packaging C hoices


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VIP ROJECT F OCUS : P LASTIC F ILM

An Overview of the Plastic Film IndustryThe Typical Plastic Film Supply ChainResins Used in Film Production

Plastic Manufacturing ProcessesPlastic Film Manufacturing

Applications of Plastic Film

To better establish a basis for evaluation and determine theinducements and barriers to the take-up of sustainablepractices within relevant firms, our research will include acollaboration with manufacturers and purchasers of theextruder and converter industry. Included here is:


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Worldwide P lastics Use

2008 (estimated)

25% all P lastics Used are Films (around 40 million tons)

U.S. Plastic Film Industry (2008)$37.68 billion in revenue

P LASTIC F ILM


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RECYCLING RATES OF FILM Approximately 812,010,000 pounds of post-consumer film

(including plastic bags) was recovered in 2006. In addition, 65%of Americans polled reuse their bags for such purposes as trashdisposal, lunch bags, and pet waste.

C ommercial F ilm = Clear, clean PE film includingstretch wrap and poly bagsM ixe d F ilm = Retail bags & Commercial; Mixedcolor, clean PE film including grocery bagsCu rbsi d e F ilm = Mixed PE film generated at aMRFA g F ilm = PE film from over wintering &greenhouse film, other

MSOffice4


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Slide 18

MSOffice4 Fixed citation in notes, 8/22/2008


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ExtractionRaw

Material Cracking Feedstock Polymerization Polymer Compounding Fabrication PackageP lastic

A CLOSER LOOK AT THE P LASTIC RESINS WITHF ILM A PPLICATIONS


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T YPES OF P LASTIC M ATERIALS U SED IN F ILMSPolyethylene (PE)

Polypropylene (PP)

Polyethylene Terephthalate (PET)

Polyvinyl Chloride (PVC)

Other:y Polystyrene (PS) and Derivativesy Polyethylene Terephthalate Glycol (PETG)y Polyethylene Naphthalate (PEN)y Polyamide (PA, Nylon)y Polycarbonate (PC)y Cellophane (Cello)y Ethylene Copolymersy Ethylene Vinyl Acetate (EVA)y Ionomersy Cyclo-Olefin Copolymers (COC)y Polyvinyl Butyral (PVB)y Ethylene Vinyl Alcohol (EVOH)y Polyvinyl Alcohol (PVOH)y Polyvinylidene Chloride (PVDC)y Liquid Crystal Polymers (LCP)y Polyarylamide MXD6 (PA MXD6)y Polyimides (PI)y Fluoropolymers


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P R O

C E S S A

S S O C I A T ED

W

I T HP L A

S T I C F I

B lown Extr u sionExtr u sion coatingC o-extr u sionC ast film Extr u sionC alen d aring

Sheet extr u sionProfile Extr u sionPipe extr u sionF oam Extr u sionP u ltr u sionStretching/ D rawingSlitting/slit-tapeC asting

M ol d ing (all forms)In-mol d d ecoratingC oatingLaminating V ac uu m d eposition/metallization V ac uu m formingPress u re formingD rape forming

Stretch formingInline formingT win-sheet thermoformingF orm- F ill-SealD igital printingF lexographyR otograv u reScreen printing

Offset printingLaser printingHot stampingHot transfer

P l a s t i c f i l mm

an uf a c t ur i n g pr o c e s s

P r o c e s s u s e d

t o enh an c ef i l m

M an uf a c t ur i n g pr o c e s s wh er ef i l mm

a y b e ani n p

u t m a t er i a

F i l mn o t i n v ol v e d


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B l o w n

E x t r u s i o n

E x t r u s i o n c o a t

i n g

C o - e

x t r u s i o n

C a s t

f i l m

E x t r u s i o n

C a l e n

d a r

i n g

Plastic film man u fact u ring process

Process used to enhance film

Manufacturing process where film may be an input materialFilm not involved

A CLOSER LOOK AT THEPROCESSES U SED TO

P RODUCE P LASTIC F ILMS


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E XTRUSION

Plastic beads are poured into a hopper wherethey are melted as they are forced down a barrelby a rotating screw. The molten plastic leavesthe barrel through a die, and the film is cooledbefore being wound onto a roll.


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E XTRUSION : B LOWN F ILM E XTRUSION

Blown film extrusion is the most common method usedfor the creation of film for packaging. The processbegins with molten plastic being extruded through andie. Air is injected in the middle of the die to blow up theplastic like a balloon. Air is also blown on the hot film

for cooling via a mounted air ring. Additional coolingtakes place as the film moves upwards as it is beingdrawn towardsrollers to bewound onto a

drum. The lay-flat film can beused as a tubeor slit into oneor more sheets.


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E XTRUSION : C AST F ILM E XTRUSION

The cast film extrusion process begins with aextruded thin film which is quenched on one sideby a chilled roll. The other side of the film iscooled by a second chilled roller. The film iswound onto a roll after passing through a seriesof rollers. The process is ideal for resins with lowviscosity and for thin films that have tighttolerances.

h ttp://www.cpc h em.com/enu/docs_styrenic/tib_204.pdf


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E XTRUSION COATING

Extrusion coating uses cast or blown film processto coat and existing roll of paper, foil or film with

plastic.

h ttp://www.totalpetroc h emicals.biz/side1/a.asp?lg=en&sid=1&ent=M&biz=b1&a=a19


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CO-EXTRUSION

Co-extrusion is the process of extruding two or more (up to 7)materials through a single die.Every material feeds into the diefrom its own extruder, where itmay provide multiple layers tothe film. Co-extrusion isadvantageous in that the finish

product inherits the desiredproperties, such as strength andpermeability, of all of the layers

h ttp://plastics.turkavkaz.ru/processes/extrusion/coextrusion/


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C ALENDERING

In the calendering process meltedplastic is passed through heatedrolls to form a sheet, and continuesdown a series of rollers with gaps of decreasing size until the requiredthickness is achieved. Afterwardsthe film is cooled on a chill roller.The equipment for calendering cost

more than the equipment forextrusion. However, the processinvolves far less cleaning than theextruder, which must be flushedand cleaned post use.

h ttp://www.plastiquarian.com/manufact. h tm


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ExtractionRaw

Material Cracking Feedstock Polymerization Polymer Compounding Plastic Fabrication P ackage

A CLOSER LOOK AT THE P ACKAGING APPLICATIONS OF PLASTIC FILM

Bags Sacs, & PouchesLabels, Sleeves, Display FilmsWrap/FilmsSemi-rigid Packaging

Tapes/Strapping


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P ACKAGING APPLICATIONS OF PLASTIC FILMLabels, Sleeves, D isplay F ilms

y Shrink Wrap Film Labelsy Shrink Sleevesy Plastic Wrap-around Labelsy Crate Labelsy Pressure-sensitive Labelsy In-mold Label

Wrap/ F ilmsy Shrink Film/Wrapy Stretch Film/Wrapy Overwrapy Bubble Wrapy Twist Wrap (Cellophane)y Lidding Film (Peel Back)

MSOffice2


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Slide 33

MSOffice2 ph oto sources added, 8/24/2008


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P A CK AG I NG A PPLI C AT IO N S O FPL A S T I C F IL M

Tapes/Strapping

y Tear Tape

y Strapping

y WeavingTape

y

AdhesiveTape

y Plastic Coated PaperboardContainers

y Trays

y

Clamshells

y Blister Packs

y

Skin Packs

y Squeezable, CollapsibleTubes

Semi-rigid

Packaging

MSOffice3


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Slide 34

MSOffice3 ph oto sources added, 8/24/2008

present state packaging

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