Strategy | sustainability
Heinz and Proctor & Gamble have looked at additional ways to meet sustainability goals. H J Heinz set a target in 2009 to reduce its overall packaging volumes by 15% by the end of 2015, which it is largely achieving through weight reduction strategies. For example, a redesign of its PET ketchup bottles has led to a 6-10% reduction in bottle weight and 20-30% cap weight reduction. The company says this has led to an overall material reduction of 2,500 tonnes. Proctor& Gamble has continued to increase its use
of renewable materials with a further expansion of its Nature Fusion bio-resin bottle, which is used in its Pantene range and comprises HDPE containing up to 45% plant-based material. Having fi rst launched the bio-resin bottle in Western Europe and the United States in 2011, the company has since expanded its use in other geographical regions. Meanwhile, packaging manufacturer Tetra Pak lists
higher recycling rates, lower CO2 emissions and commercialisation of what it claims is the world’s fi rst
100% bio-based carton as part of its 2020 environmen- tal goals. The company says its Tetra Rex Bio-based carton system is comprised solely from paperboard and plant-based plastics, including the TwistCap OSO 34 bio-based closure. The package is currently being trialed by Finnish dairy producer Valio in retail outlets across the country. The TwistCap is made of high density polyethylene derived from sugar cane and supplied by Braskem. Emissions of CO2 across all parts of the Tetra Pak
value chain were down 8% from a 2010 baseline, despite a 7% increase in production over the same time-frame. Tetra Pak has a 2020 target of maintaining its climate impact at 2010 levels while growing the business. Within its own operations, Tetra Pak emissions were 1.5% lower than in 2010, while production levels were up 13%. The company adds that in 2014, 651,000 tonnes of used beverage cartons were recycled globally, up from 623,000 tonnes in the previous year. This represents 26% of the company’s annual delivery, although it is still some way short of its 2020 target of 40%. Earthwards is a step-by-step process introduced by Johnson & Johnson to evaluate its product environmen- tal performance across several key areas. This includes the sustainability of its packaging and the company is looking at a number of ways to improve its environmen- tal footprint, including optimising the amount of packaging in its products. A recent example is packag- ing for a complexion cream product where the bottle weight has been reduced by 23% and carton material by 32%, saving a signifi cant amount of PET annually. In addition, the company is increasing its use of
recycled plastics in its packaging. It is currently using up
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to 25% post-consumer recycled (PCR) content and has established additional initiatives to boost PCR recovery in communities where it operates. For example, the company is working with a recycling cooperative called Futura in Brazil to improve working conditions, health and safety practices and overall productivity at a recycling facility close to one of its own manufacturing locations. It says this is the fi rst recycling co-operative in the world to achieve the SA8000 certifi cation for its workplace and labour programmes.
Automotive initiatives
Car manufacturers are also keen to enhance sustain- ability credentials with regard to the materials – includ- ing plastics - used in their products. For example, Ford Motor Company’s Sustain- able Materials Strategy is designed to infl uence the safety, fuel economy and performance of the vehicle, as well as the options available to recycle or reuse the vehicle’s components at the end of its life. The company defi nes a sustainable material based on a
number of factors, including its origin (virgin, renewable or recycled), the natural and human resources and manufacturing methods used to process it, the emissions produced throughout its life cycle, and its application.
Ford says it considers the impact of materials at every stage of a vehicle’s life cycle and is increasing the use of sustainable materials and eliminating undesirable ones. Among the ways the company is achieving this is by replacing petroleum and other non-renewable resources with plant-based materials.
Recent examples include an
injection moulded, cellulose fi bre compos- ite console for the Ford Lincoln MKX. The PP part includes 20% cellulose fi bre content. It costs the same as the glass reinforced PP component it replaces but
reduces CO2 emissions by 11%, due to a combination of a 6% weight reduction and a 10% process energy reduction. The reduction in process energy is possible because the natural fi bre reinforced grade can be moulded at lower temperatures. Another recent Ford material replacement example
is the rear deck-lid applique and side door cladding used on the current Ford Mustang. The part is a TPO that uses mineral fi bres and coconut powder in place of
Above: The bio-based
HDPE Twist- Cap OSO 34
closure from Tetra Pak is
being trialed by Finnish dairy producer Valo
September 2015 | COMPOUNDING WORLD 81
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