sustainability through flexible · pdf filefavors flexible packaging the epa recognizes waste...

Sustainability Through

Flexible Packaging

innovation in action

About Ampac


Broad Global Presence

About Ampac


Ampac Business Units

About Ampac

Security Retail

Flexibles


Global Market Expansion

Innovation and proactivity builds customer relationships and

provides growth

1997 2001 2011

Manufacturing Centers

1 2 14

Countries with

Operation USA USA

USA, China, Southeast

Asia, UK, Switzerland and

Germany

People

210

440 1,500

Markets Retail Packaging Retail and

Food Packaging

Food, Medical,

Pharmaceutical,

Retail and Security

Packaging


2000 2002 2004 2006 2008 2011

Specialty

Retail

Products

Security

Packaging

Products

Flexible

Products:

Coextruded

Films

Flexible

Products:

Pouches &

Laminations

Global Market Expansion


Ampac Operations

Flexible Packaging Solutions

Film coextrusion

Printing – Rotogravure,

flexographic, high process

Laminating

Pouching



Ampac Operations

Core Markets

Pharmaceutical / Medical

Food

Pet Food Financial

Institutions / Banks

Retail



Improved Filling Efficiencies – zipper on one side of the

pouch prevents issues filling through zipper or opening

zipper Easy Opening – straight and easy tear; no tearing into

product or need for scissors Easy Re-open – header offset provides easy re-access

to zipper Improved Branding – package remains intact

Header remains to provide branding and copy

space, easy access space for date coding that

remains with the pouch. Easy for consumer

EZ-ZIP® Key Attributes and Benefits


Ampac Operations


Key Attributes and Benefits

Unique Unit Dose Dispensing – flatter rigid

package with controlled single dose dispensing

Broad Market Reach – food and non-food,

medical, health and beauty, cosmetics

Filling / packaging machine partner – Easypack

Solutions

Butterfly Pack


Ampac Operations


Sustainability


Sustainability

“Sustainable development meets the needs of

the present without compromising the ability of

future generations to meet their own needs”

(U.N. 1987 World Commission on Environment

and Development).

Sustainability includes the concept of the Triple

Bottom Line: the interpretation of financial,

environmental and societal aspects of an

organization and business decisions.


Oxodegradable

PE with catalyst additive; catalyst causes the PE to break down in the presence

of oxygen, heat, or light but PE fragments remain

Compostable

Compost satisfactorily, including biodegrading at a rate comparable to known

compostable materials. Assure the degradation will not diminish the value or

utility of the compost – meet ASTM D6400

Renewable

Produced with renewable (generally non-petroleum) materials. Can be 100%

or partially renewable.

Recyclable

Products that can carry a #2, #4 or #5 symbol or that can be certified through

partner programs (Terracycle, Trex, etc.)

Improved Process

Produced using less natural resources (energy) than a comparable product

(e.g. solventless laminate vs. solvent uses 86% less energy)

Sustainability


Packaging Market

innovation in action © 2010 Flexible Packaging Association

U.S. Packaging Industry Overview

Source: Latest U.S. Census Bureau data & Flexible Packaging Association estimates 2009

Others

15%

Glass

3%

Misc Rigid

Plastics & Bottles

16%

Metal Cans

12%

Flexible

18% Paperboard

11%

Corrugated

24%

Flexible Packaging:

“Any package or part of a package that can readily change shape. It includes packaging utilizing paper,

plastics, film, foil or any combination of these materials.”

U.S. Flexible Packaging End-Use

Markets $ 25.9 Billion

Total US Packaging $136 Billion


0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

2009 2010 2011 2012 2013 2014

10.4 11.0

11.5 12.1

12.4 12.8

NA Food and Beverage Pouch Market

2009-2014

Bill

ion U

nits

Stand-up Pouch growth

***4.2% and $2.4 Billion*** *Year on year growth % Source: Euromonitor 2011

Stand-up Pouches Expected Grow


Flexible Packaging and Sustainability


Some Obvious Advantages of Flexible Packaging

Can Be Customized to Meet Product Needs

Offers Great Shelf Appeal

Conveys Product Information

Provides Consumer Convenience

Reclosability

Microwaveability

Extended Shelf Life

© 2010 Flexible Packaging Association


Less Obvious Advantages of Flexible Packaging

FPA research confirms that flexible packaging:

Lighter weight, provides better product-to-package ratio

Efficient storage (warehouse, retail, home)

Fewer trucks on the road and less emissions

Uses fewer resources and less energy over life cycle

Results in less CO2 emissions

Reduces Product Spoilage & Waste



FPA/Battelle Streamlined Life Cycle Assessment

20



Food Chain Energy Consumption

drive to stores,

storage,

cooking, 30%

food production,

50%

transport &

retailing, 10%

packaging, 10%

Of total energy used in the food chain

50% used in food production

10% on transport to stores

10% to make primary, secondary and tertiary packaging

30% is used by shoppers to drive to the shops and store and cook food

Source: “Packaging in Perspective” prepared by the Advisory

Committee on Packaging (UK)


Flexible Packaging Reduces Waste

Bag-in-a-box packaging produces 2.9 times

more MSW than stand-up flexible pouches.

Stand-up flexible pouches are 63% less

weight compared to bag-in-a-box packaging.

Stand-up flexible pouches are 96.7% less weight

than glass bottles and 40.4% less packaging

weight than aluminum cans.

Glass bottle is 20 times more landfill material by

weight.

Source: FPA Case Studies, 2009

Less Packaging Weight = Less Waste in the First Place

Plus Greater Transportation Efficiencies


Flexible Packaging Uses Less Resources

Saves transportation miles & fuel consumption

60 pounds of

beverage

50 pounds of

glass

6 pounds

of Rigid

PET

3 pounds of

aluminum

1.5 pounds of

Flexible

plastic

= = = =

Sources: Dow Presentation; FPA Case Studies, 2009


Flexible Packaging Improves

Transportation Efficiency

Reducing Fossil Fuel Consumption and CO2 emission

Lessening Highway Wear/Tear and Congestion

26 Truckloads of

Unfilled Glass

Jars

One Truckload of

Unfilled Plastics

Pouches

Less Fuel

consumed & Less

emissions

= =

Source: DuPont Awards for Packaging Innovation

(Pasta Sauce Flexible Pouch Example)


Flexible Packaging Sends LESS to the Landfill

MSW Landfill per

100 g Product (g)

Beverage Packaging Example:

6.0

54.5

2.4

2.8

Sources: FPA Case Studies, 2009; EPA 2007 MSW Report

To

MSW

Landfil

l

65%

63%

51%

100%

Product

Weight

(g)

Package

Weight

(g)

Package

Wt per

100 g

Product

(g)

Recycle

Rate

Glass Bottle

& Metal Cap 236 198.4 83.9 35%

Plastic PET

bottle & Cap 236 22.7 9.6 37%

Aluminum

Can 236 11.3 4.7 49%

Flexible

Stand Up

Pouch 199 5.7 2.8 0%


Beverage Packaging

Beverage

Packaging

Product

Weight

Packaging

Weight

Product-

to-

Packaging

Ratio

Packaging

Weight

per 100g

Product

MSW

Landfill

per 100 g

Product*

Energy

Consumption

MJ/8 oz

Emissions

Kg CO2

e/8 oz

Glass Bottle

& Metal Cap

8 ounces

(236 g) 198.4 g 1:1 83.9 g 54.5 g 3.36 0.29

Plastic PET

Bottle & Cap

8 ounces

(236 g) 22.7 g 10:1 9.6 g 6.0 g 3.00 0.18

Aluminum

Can

8 ounces

(236 g) 11.3 g 21:1 4.7 g 2.4 g 0.99 0.08

Stand-up

Flexible

Pouch

6.75

ounces

(199 g)

5.7 g 35:1 2.8 g 2.8g 0.45 0.02

Product assumed to be water

*Recycling rates factored: U.S. EPA 2007 MSW Report.

Cradle-to-grave life cycle energy consumption and CO2 emissions data developed for FPA by Battelle Memorial Institute.

Packaging weight, product weight, and product-to-packaging ratio calculated by Packaging & Technology Integrated Solutions, LLC (PTIS)



Flexible Packaging End-Of-Life Cycle Options

Flexible Packaging Supports Source

Reduction

(EPA’s most preferred waste management strategy)

Flexible packaging offers significant potential for energy recovery from

waste.

Source

Reduction

and Reuse

Recycling

Composting

Waste to Energy

Landfill or incineration

with no energy recovery

Most

Preferred

Least

Preferred

U.S. EPA Solid Waste Management Hierarchy


Waste to Energy: A Renewable Source of Energy

Favors Flexible Packaging

The EPA recognizes waste to energy as a clean, reliable,

renewable source of energy.*

The U.S. converts only 29 million tons of solid waste to

energy annually. This is equivalent to a savings of 29

million barrels of oil or 10 million tons of coal annually.

*Letter from U.S. EPA to Integrated Waste Services Association, February 14, 2009

Source: FPA/Battelle Study, 2009

1 ton combusted MSW: MSW = Municipal Solid Waste

1/3 ton coal

1 barrel oil = =


WTE Generates Less Emissions

Fuel Carbon

Dioxide Sulfur

Dioxide Nitrogen

Oxides

(lbs/MW.h)

Energy from Waste 837 0.8 5.4

Coal 2249 13 6

Oil 1672 12 4

Natural Gas 1135 0.1 1.7

Source: FPA/Battelle Study 2009, “Comparison of Air Emissions from Waste-to-Energy Facilities to Fossil Fuel Power Plants,”

Jeremy O’Brien, Solid Waste Authority of North America, www.swana.org

Currently WTE facilities emit less GHG emissions than fossil

fuel energy plants



Examples


What is the next package format as categories evolve?

Migration from Rigid to Flexible



Recyclable

Outter shell 100% recycled board

In side No. 4 pouch and fitment.

Broad Market Range – any “flowable” product; food

and non-food.

Seventh Generation Laundry Soap

Launch May 2011

Ecologic Pouch

Rigid Functionality with Flexible Benefits


Retort Pouch vs. Glass Jar – Packaging Weight

33

Rigid Replacement


Pouch vs. Glass Jar – Walmart Scorecard Impact

-20%

0%

20%

40%

60%

80%

100%

Pe

rce

nt C

ha

ng

e

Packaging Knowledge Group LLC

34

Rigid Replacement


Rigid Replacement


Box Pouch

Less weight that traditional box with liner

Better cube utilization than bottom gusset pouch

Truly flat bottom for better stand up display

Window displays front, sides or bottom

Rigid Replacement


Vapur® Anti-Bottle

Replaces disposable rigid PET water

bottles

Refill with drinking water from tap

Rolls up and fits into pocket when

empty

Antimicrobial inner layer

Dishwasher safe

Reusable Flexible Water Bottle

Rigid Replacement


Rigid Replacement


HDPE pouch, can be labeled with SPI number 2 triangle

Easier to recycle compared to multi-ply, laminated pouches; recyclable with plastic, retail shopping bags

Positive step for environmentally influenced purchasing decisions

Approved by Trex® Company for post consumer recycling into outdoor decking and railing

processor of 70% of all plastic bags recycled in the US

Good MVTR Barrier

Resealable zipper

High definition flexo printing

Available in roll stock for FFS packaging

Recycleable Stand-up Pouch

No. 2 PouchTM



Biodegradable/compostable stand-up

pouch with resealable zipper

Meets ASTM D6400 requirements for

municipal composting

50% Renewable resource (cellulose)

content

Made with Innovia Natureflex™ films

Saran coated for oxygen and moisture

barrier

Compostable Bio Pouch

Thank You! Questions?

sustainability through flexible · pdf filefavors flexible packaging the epa recognizes waste...

Documents