resource efficient packaging andy dawe head of retail programmes wrap

Resource efficient packaging

Andy DaweHead of Retail Programmes WRAP

Presentation outline

•Introduction to WRAP•Why is packaging optimisation

important?•Recycling•Delivering optimised packaging•Tools to help

Introduction to WRAP

WRAP – Waste & Resources Action Programme

• Private company, funded by Defra and the devolved administrations

• WRAP helps individuals, businesses and local authorities to reduce waste and recycle more, making better use of resources and helping to tackle climate change.

Our priority areas

Packaging

CollectionSystems

Quality ofMaterials

Food Waste

THE RESOURCE EFFICIENCY LOOP

Why is this important?

Prime Minister’s Strategy Unit

New Packaging Strategy, to be developed within the framework of the Waste Strategy for England (2007)

Encourage prevention, reuse and recycling

Improve information flow

New Courtauld Commitment style voluntary agreements for packaging reductions by 2012 and new objective to encourage use of recycled materials

Courtauld Commitment

The signatories commit to supporting WRAP in the achievement of its objectives:

• To design out packaging waste growth by 2008

• To deliver absolute reductions in packaging waste by 2010

• Reduce the amount of food wasted in UK homes by 155,000 t by March 2010

Removal of packaging at check-out

Source: The Guardian, 15th November 2006

• Landfill: zero food and packaging waste to landfill from 2015

• Commercial and industrial wastes: to achieve a 20% absolute reduction in food and packaging waste arising at food and drink manufacturing premises by 2010 against a 2006 baseline

• Primary packaging: to make a significant contribution to WRAP’s work to achieve an absolute reduction in the level of packaging reaching households by 2010, compared to 2005

• Labeling and information: to provide more advice to consumers on how best to recycle or otherwise recover used packaging

Waste prevention reviews

Supporting the FDF's 5 fold Environmental Ambition

Thinking differently through considering food and packaging from factory to fork with 'lean' thinking in resource efficiency

Will develop and share good practice through case studies

A number of benefits are being quantified - cost and carbon

Integrating primary, secondary &

tertiary packaging Cereal carton size 50T CO2

14T

44T CO2

4T

6T CO2 264m2X 10

Materials: carton board and corrugated storage distribution

For 1million cereal packets sold:

By reducing the carton of a cereal pack by the dimensions of a small matchbox (8 x 35mm) the end result would be a reduction in material usage of 18T (50T CO2), saving of finished goods storage area equivalent to a tennis court (264m2) and

the removal of 10 vehicles off the road for trunking of stock.

Recycling

Last year 8.7 million tonnes of waste was recycled in England alone.

More than doubled in the past 5 years.

Yet recent negative reports question its worth.

IS RECYCLING WORTH IT?

We need three earths to sustain the way we live today.

It is key that we address this issue now as there is still much more to be done.

Markets are stabilising and demand is increasing. End markets are being explored. Recycling is working but we must continue the

momentum. We must focus on the resource efficiency loop which

will bring real benefits to the economy.

Delivering optimised packaging

Your options:• Remove packaging completely• De-layer the pack• Reduce the number of components in a pack• Down-gauge packaging material (make it thinner)• Light-weighting and right-weighting a pack• Right-sizing (reducing the head space in a pack or offering a

range of portion sizes to customers)• Refill packs / reusable packs (simplification?)• Changing packaging formats and materials• Structural re-design or re-engineering of the pack• Concentrates, product compaction and reformulation

De-layering: Cadbury’s Treasure Eggs

Tesco 68% less packaging

Starpack Gold Medal Winner

De-layering and simplification:

M&S: 69% less packaging and

6 days more shelf-life

Thinking Differently

• Thermoformed trays replaced with vacuum pack or flow wrapped bags

• ‘Organisation rails’ provide order and consistency to presentation

• Extra surface area used for product and brand communication


range of portion sizes to customers)• Refill packs / reusable packs (simplification?)• Changing packaging formats and materials• Structural re-design or re-engineering of the pack• Concentrates, product compaction and reformulation• Pack innovation (breaking the category rules?)

Reducing packaging componentsSavings:•Greencore Frozen Foods has

reduced the pack weight of five different products by an average of nearly 70% during 2007, saving 115 tonnes of plastic

•Move away from packing in multiple plastic trays inside bags to new “form and fill” technology, whereby products are placed loose in film bags.

•More products can fit on each pallet – helping to reduce transport needs

Can light-weighting

Savings:•5% weight saving (15,000 tonnes)•New can body target thickness is only

0.097mm wide – about the width of a human hair

•Over 6.5 billion cans so far, saving 88,000 tonnes of CO2

•Average 50% recycled content

Manufacturer:•Beverage Can Makers Europe

Brand-owner:•Coca Cola (Europe) Ltd

Aluminium can light-weighting

Structural re-design

The old and new Coca Cola

Contour bottles

Ultra lightweight formats

10g ‘no-

bottle’ USA

Your options:• Remove packaging completely• De-layer the pack• Reduce the number of components in a pack• Down-gauge packaging material (make it thinner)• Light-weighting and right-weighting a pack• Right-sizing (reducing the head space in a pack or

offering a range of portion sizes to customers)• Refill packs / reusable packs (simplification?)• Changing packaging formats and materials• Structural re-design or re-engineering of the pack• Concentrates, product compaction and reformulation• Pack innovation (breaking the category rules?)

Optimisation tactics – Reducing headroom


range of portion sizes to customers)• Refill packs / reusable packs • Changing packaging formats and materials• Structural re-design or re-engineering of the pack• Concentrates, product compaction and reformulation• Pack innovation (breaking the category rules?)

59g

23g

Refills offer easy materials savings opportunities and the ability to innovate

Innovation in refill packs and ease of use

The old and new Boots ‘Botanics Essentials’ gift sets

Pack simplification and reusability

Reuse is even better

Project Sofa

Returnable packaging

Logistics are key

Changing pack format and materials

Weight: 54g

15g 49g

Format Change

•Same quantity of soup in a third of the material.

•Pouch is the premium product

Asda Café Sandwiches:• 56% packaging savings• Better product

visibility• Flow wrap retains

freshness for longer• Better cube efficiency

in distribution

Before: 16g

After: 7g

Structural re-design

By using a folding box design rather than the former box and lid, the company has reduced the weight of the packaging from 68g for 200g of product to 26g for 160g of product, achieving a 48 per cent weight for weight saving.

Complete product reformulation

2 x concentrated fruit squash

Double concentrated squash means the 3L squash bottle has been replaced with a 1.5L bottle, generating a bottle weight saving of 35g (46%) and avoiding the need for a handle.

This innovation generates a saving of 469 tonnes of plastic per year.

Some tools to help

Thank you

resource efficient packaging andy dawe head of retail programmes wrap

Documents

used packaging slide

recycling slide

carbon slide

removal of packaging

packaging reductions

packaging waste growth

level of packaging

waste strategy