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Jim Scott, JES PackagingJim Scott, JES Packaging
PackExpo ‘09 Las VegasPackExpo ‘09 Las Vegas
October 6October 6thth, 2009, 2009
Man vs. Clamshell: A Lopsided Fightby David Segal, NYT, 9/27/09
“… companies want packages that are easy to transport, display products in a highly visible way and are hard to steal …
The point is to create a package that cannot be opened and closed surreptitiously.
That way, no one can remove anything and put the package back on the racks without it being obvious.”
History of Trend toward PCR Plastic Packaging
Sheet Extruders’ Imperatives
Thermoformers’ Imperatives
End Users’ Imperatives
Retailers’ Imperatives
Recyclers’ Imperatives
Why Trend toward 100% Post-Consumer Content Recycled Plastic Packaging will Continue
’80s – ’90s – Paperboard Pkg. “100% Recycled Content - Min. 35% Post-Consumer Content”
Non-Food Contact due to FDA Concerns
Late ‘90s – ’08 – Increasing interest in “Bio-Plastics,” eg., PLA – sometimes touted as
“biodegradable”
‘05 – Wal-Mart initiates its “Packaging Scorecard”
‘06 – ’09 – Increasing Questions on Performance, Cost, and Sustainability of Bio-Plastics and degree of biodegradability / compostability
‘08 – “Wal-Mart will become more aggressive in the near future: Material Reduction & Recycled Content”
‘08 – ’09 – Increasing demands by Major Retailers with “Truth in Environmental Labeling” mandates
‘09 – Wal-Mart initiates its Sustainable Product Index
Greener Package initiates its “Anti-Greenwash” Guidelines
Pentel introduces Recycled “Handy-line S” Highlighters
More Sustainable versus Virgin or Bio-Plastics
Equal or better Physical Characteristics and Performance
Availability and Competitive Cost of FDA Food Contact Pellets and Flake … esp. PCR PET
Claims can be readily Substantiated … and meet “Truth in Labeling”
Mandates
Supported by CPG Companies and Major Retailers
Sheet Extruders’ ImperativesSheet Extruders’ Imperatives Want Proprietary Manufacturing Processes and Equipment
Capability to run Flake … not Pellets … may be necessary for High Quality and Consistency of RPET
Need Multiple sources of Pellet / Flake, esp. FDA food grade RPET
May need to move in stages from 35% to 100% Post-Consumer Content
Due to new or less efficient processes … or increased demand … may need to significantly increase Production Capacity
Thermoformers’ ImperativesThermoformers’ Imperatives
Want Proprietary Manufacturing Processes and / or Package Styles
Need to offer Cost Competitive, Sustainable Packages
May need to move in stages from 35% to 100% Post-Consumer Content
ThermoformersThermoformersCharacteristic PVC PLA PET RPET Forming Throughput X ? + 5% + 5% Energy / Higher ? Lowest Lower? Oven Temp. 600 F ? 450 F 450 F Shrinkage / Equal Equal? Equal Equal Mold Heated Die / No ? Yes Yes Plate Die Wear Slow ? Fast Fast Cutting Less ? More More Pressure
End Users’ ImperativesEnd Users’ Imperatives Want Unique Products and /or Packaging vs. Competition
No Increase in Cost, but … No Sacrifice in Production Efficiency or Performance
Driven mostly by Major Retailer Demands … esp. WalMart * Cost has been #1, #2, and #3 * Environmental Issues beginning to be seriously considered
On-Package Environmental Claims must be believable to Consumers … and be readily Substantiated
End UsersEnd UsersCharacteristic PVC PLA PET RPET Clarity Best Good Best Good / Best “Environmental Least Best Good Better I mpression” Enviromental No No No Yes Claims can be Substantiated Recycled Content No No No Yes Recyclable No No Yes Yes
End UsersEnd UsersCharacteristic PVC PLA PET RPET I mpact Strength 415 300? 425 425 ASTM D1709 - gm. Adh. for Face Water / Water / Solvent Solvent Cards Solvent Solvent Water? Water? Adh. for Fold W / S W / S W / S W / S Cards
Cost X 3X 1.2X 1.2X
Earthbound Farm Earthbound Farm America’s largest grower of Organic
Produce
July, ’09 - announced that all their clamshell fresh cut salad pkgs. are being made from 100% post-consumer Recycled PET
RPET is being supplied by Packaging Plus
Earthbound Farm Earthbound Farm
Based on 2008 Annual Usage, use of 100% RPET:
Will conserve 424,000 million BTUs
Will conserve 68,307 gallons of water
Will eliminate 16,191 tons of CO2
Will divert 1.3 million lbs. of Solid Waste from landfills
Sustainable Packaging Coalition Sustainable Packaging Coalition (SPC) (SPC)
“ Earthbound Farm’s PCR PET initiative is a perfect example of how to get the ball rolling in the right direction.”
“We hope to see more companies that make that commitment, creating a market for these materials …”
Anne Johnson, Director SPC
Subway Subway Changing Plastic Salad Bowls:
Redesigned to reduce use of plastic
Switched from OPS to 10% PCR PET
Will reduce plastic material use by 712,00 lbs. annually
Will eliminate 19,500 corrugate cases annually
Will reduce carbon footprint by 21% or 84.8 kgm of Carbon Dioxide Equivalent (CO2e)
PWP Industries PWP Industries
Major supplier of FDA Food Grade RPET
Supplier of the 10% PCR PET for Subway
June, ‘09 - opened 40 million lb. annual capacity PET Recycling facility in West Virginia at cost of $20M
Second 40 million lb. facility scheduled to open Q2/10 in California
Every 40 million lbs. of RPET represents elimination of 30,000 tons of CO2 and 398 million kilowatt hours … annually
Integrated Packaging FilmsIntegrated Packaging Films
ECO-THERMECO-THERM tmtm 100% Post-100% Post-Consumer Recycled PET sheetConsumer Recycled PET sheet
Made with FDA food contact RPET resinMade with FDA food contact RPET resin
PreservePreserve
Preserve toothbrushes made from 100% Post-Consumer Recycled Polypropylene (PP) - Yogurt Cups
Packaging Clamshell made by Innovative Packaging from ECO-THERM tm 100% Post-Consumer Recycled Content PET
Preserve’s Claim: “Plastic packaging made from 100% post-consumer plastic bottles”
Schering-Plough, Corp.
OTC offerings include Claritin allergy pills, Afrin nasal sprays, Dr. Scholl’s foot care products, and the sun care line Coppertone
Products marketed in some 140 Countries
Company has agreed to be acquired by Merck
Schering-Plough, Corp.
New Package Requirements:
Must work in “Club Store” setting
Sustainable material
Does not require the purchase of Sealing Equipment
XO Athletic Company Over 20 Years experience in the
Sports Medicine market
Supplying over 80% of the US athletic cup market
Invented the “flexible cup” in 2000 – hard cup covered in soft rubber
XO Athletic Company
New Package Requirements:
New, smoother design that is more in line with product
Clamshell
Does not require the purchase of RF sealing equipment and can be packaged “in house”
More Sustainable material
XO Athletic CompanyPackaging Development:
June 2009: First Choice met with CardPak and LucDesigns Engineering, LLC. to discuss XO Athletics’ concepts
XO Athletic Company
Packaging Development
End of July 2009: Presented full display planogram to major retailer
Sept 2009: Moving forward on production order for Fall 2009 introduction
NEW PACKAGING FOR 2010
XO PROCUP Current New
XO PROCS2
Current New
ScarGuard Labs, LLC, Inc.
A Pharmaceutical Company guided by Doctors, Pharmacists, and Pharmaceutical Biochemists with decades of combined experience
Manufactured in three locations across the U.S.
ScarGuard MD and ScarLight MD available at Doctors’ offices and Retail Outlets (CVS, Walgreens, etc.)
ScarGuard Labs, LLC, Inc.
New Package Requirements:
Eliminate material splitting
More Sustainable material
Improve product fit
Lower Costs
ScarGuard Labs, LLC, Inc.
ScarGuard Labs, LLC, Inc.
Retailers’ ImperativesRetailers’ Imperatives
Desire to provide Value to Consumers leads to constant pressure on Consumer Products Companies for lower and lower prices
Pressure from Environmental groups for major Retailers to act as quasi-governmental bodies by setting Sustainability standards
Opportunity to work with Recyclers on Closed Loop Recycling Programs to increase Post-Consumer Content
RetailersRetailers
Characteristic PVC PLA PET RPET
Environmental No No No YesClaims can beSubstantiated
Cost Effective Most No Yes Yes
Can Survive Yes No Yes YesDistribution
Recyclers’ ImperativesRecyclers’ Imperatives
Need to have a Critical Mass of packages in a recognized Recycling group to make it profitable to separate
Need to have a minimal number of packages in the Waste Stream that contaminate the Recycling System, eg., PVC or PLA
Opportunity to test PET, PP and PS Recycling Programs with companies like A Greener Solution or NextLife
RecyclersRecyclersCharacteristic PVC PLA PET RPET Ease of No No Yes Yes Separation Contamination Yes Yes No No I ssues Market for No No Yes Yes Resale
Continued Improvement in Physical Characteristics and Performance
Continued Availability of PCR Resins … esp. FDA Food Contact RPET … Large potential Source: 166 Plastic Bottles per year
… but only 20% are presently recycled
Claims can be readily Substantiated … and meet “Truth in Labeling” Mandates
Potential for Increased Government Legislation
Consumers recognize that Recycled Content Packages have positive environmental impact
Continued comfort with “Post-Consumer Recycled Content” Claims … even on Food Packaging
Continued Support by Major Retailers and CPG Companies
Opportunities for PP and PS Recycling … with companies like A Greener Solution or NextLife
Continued Competitive Cost
Jim Scott, Principal JES Packaging
(401) 597-0761 [email protected]