Packaging Standards Supplier Instruction Document · carbon footprint in the chain, and packaging has a part to play. By reducing the overall weight and ensuring minimal size of transit

1 Packaging Standards – Supplier Guide V2

Packaging Standards

Supplier Instruction Document

Supplier Guide

2 Supplier Training - Inbound Supply Manual Spring Summer 2016

June 2016 v 2.0

Purpose of this Manual

We have created this document to share information with you about what Inbound Supply

expectations we have relating to deliveries made into our distribution centres at Tesco.

This document provides you, as a supplier, with the details of our distribution centre needs in

order to avoid costly rejections from our sites and support the improvements in availability of

your stock, whilst reducing cost throughout the supply chain.

This document makes specific reference to packaging standards and is designed to provide

all the necessary details of everything to consider and what testing is considered appropriate

for packaging creation when providing stock for Tesco – this will help eliminate the number

of damages within the supply chain and ultimately provide excellent quality of goods for the

customer.

PACKAGING


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Tesco Distribution is committed to ensuring the most appropriate packaging is used

for the containment, protection and sale of its products. Working with our suppliers

this section will give the information required to ensure packaging it fit for purpose,

while using the most environmentally friendly materials

General Packaging Requirements


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All packaging should be fit for purpose and designed to fulfil the following criteria:

a) Provide adequate protection of the product throughout the supply chain b) Provide containment of the product and all its components c) Comply with all relevant legislation d) Satisfy the requirements of the Environmental Policy e) Be easy for the customer to dispose of (RECYLE) f) Be aesthetically pleasing to the customer g) Be economical whilst meeting all of the criteria above

General Packaging Requirements (continued)


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Legal Obligations

Packaging (Essential Requirement) Regulation 2003

These are specific to the composition of all packaging, implementing parts of EU Directive 94/62/EC

on Packaging and Packaging Waste. These regulations cover the key issues of minimising materials

used and the end life environmental impact.

In summary:

Packaging should be manufactured so that the packaging volume and weight is limited to the minimum adequate amount to maintain the necessary level of safety, hygiene and product protection.

Packaging should be designed and produced in such a way as to permit its reuse or recovery including recycling and to minimise its impact on the environment when packaging or residues from packaging waste are disposed of

Packaging shall be manufactured to ensure that the presence of noxious and other hazardous substances and materials as constituents of the packaging material or any of the components is minimised with regards to their presence in emissions ash or leachate when packaging on its residue are incinerated or landfilled

Heavy metals content should be no greater that 100ppm TOTAL in any packaging

Producer Responsibility Obligations (Packaging Waste) Regulations 2007

A levy is imposed on the use of packaging materials (or Packaging Waste) by weight

To comply with these regulations Tesco must know the weight of packaging that it handles annually.

As a result, all suppliers of own brand and branded product provide us with a line by line breakdown

of the weight of packaging. The packaging levy placed on each pack is dependent on the materials

used such as paper, plastic and glass.

To minimise the cost to Tesco, the weight of the packaging must be minimised subject to the

constraints of safety, logistics and marketing in compliance with the Packaging (Essential

Requirements) Regulations 2003

Key Environmental Principles for Packaging


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Working with industry leaders, packaging suppliers and product suppliers, we have established some

key principals to ensure that we apply a consistent approach to our packaging selection. Their

importance will vary depending on specific product categories.

It is fundamental that we develop a holistic approach that considers packaging performance and

environmental impact across the supply chain from source to the customer, without creating extra

waste or environmental impact elsewhere.

We aim to delight the customer by delivering a product that has been well protected by the packaging,

whilst ensuring ease of packaging disposal.

1. FIT FOR PURPOSE Packaging specification must not compromise the pack’s ability to fulfil its primary functions of:

Product protection and preservation

Promotion (communication and selling)

Performance (functionality in use such as ease of handling)

Packaging reduction causing an increase in product damage would not be ‘fit for purpose’

2. LIGHTEST WEIGHT OF MATERIALS TO DO JOB

Wherever possible we will aim to use the lightest pack to do the job without compromising product

protection or performance.

3. SUSTAINABLE MATERIALS

For paper and board, consideration should be given to the best route for paper and board, balancing

the environmental credentials with commercial as appropriate. Tesco has committed to use legal

sources for wood and paper. When selecting recycled board or paper, suppliers will be able to

specify either a virgin source or a recycled content source. A recycled source will benefit the

environment by encouraging the recycling stream to exist. However, a recycled board is generally

heavier than their virgin equivalents (a recycled board tends to be thicker than virgin for carrying out

the same function). If a virgin board is selected, then it should be from certified sources, with the FSC

certification being the choice of preference.

Overall, either recycled board or certified virgin board is acceptable, but due care and consideration

should be given to the overall balance of weight and functionality.

4. RECYCLABLE AND RECOVERABLE

Our choice of packaging material and design should maximise opportunities for recovery through

recycling.

5. LOW CARBON IMPACT


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Suppliers need to ensure that fit for purpose transit packaging is used. Our policy is to minimise the

carbon footprint in the chain, and packaging has a part to play. By reducing the overall weight and

ensuring minimal size of transit packaging, the carbon footprint will be minimised. However, the

packaging must protect the product for transit as all carbon benefits will be lost if the product itself

becomes damaged. The key message is to provide absolute product protection with the least amount

of transit packaging possible.

6. REDUCE UNUSED SPACE

Minimise pack headspace by modifying filling process or changing packaging format

7. OPTIMISE PACK DIMENSIONS

Identify best pack dimension to optimise space in distribution and minimise primary, secondary and

tertiary pack materials

8. REDESIGN THE PRODUCT * for DIRECT ONLY

Could the product be reformulated to reduce packaging and move to most economical channel? – I.e.

Move from 2 Man to 1 Man by making the product pack into a smaller dimension.


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Packaging Performance

Check with your relevant Commercial contact to establish any performance testing that you may need

to carry out and pass to supply products to Tesco. It is recommended that your packaging will pass

the Tesco Stack Test: details below

Tesco Stack Test

Purpose

All Tesco products are shipped and stacked in different ways throughout the supply chain. When

items are stacked on top of each other damage can potentially occur when the stack weight exceeds

the stacking resistance of the packaging. This is why we need a stack test.

The stack test will simulate the effects of tower stacking on a product. One carton is to be tested

under an ‘apply-and-hold’ dead weight test (based on the test approach described in test method

ISTA 3E warehouse compression test) using a load simulated with weights.

You must test actual product prior to shipment, the boxes should contain the product they are

intended for. It is the transit pack that you are testing

WARNING: EXTREME CAUTION TO BE TAKEN WHEN CONDUCTING THIS TESTING,

HEAVY WEIGHTS INVOLVED


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Tesco Stack Test (continued)

The load needs to be calculated using the following formula:

WARNING: EXTREME CAUTION TO BE TAKEN WHEN CONDUCTING THIS TESTING,

HEAVY WEIGHTS INVOLVED

A load spreader must be used to ensure

the weight is evenly distributed across

the carton.

Monitor any changes in the carton over a

48 period while the carton is under the

test load – take photos before and after

testing to monitor any change

If the box shows any signs of damage, it

has failed and you need to increase the

strength of the material


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Handling Labels

There are two main handling labels that must be used dependent upon the product weight. These are

to be attached to a visible area on the exterior of the pack.


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Labelling Multiple Item Sets

Where products are sold as multi item sets, a label must be attached to each item indicating the

product number and the total number of products in the set.

The contents of each pack/carton must remain consistent throughout the life of the product. Any

changes to the pack contents configuration must be agreed in advance with the Tesco Commercial

Team

Cautionary and Handling Advice Labelling

In addition to the individual pack identification labels the product should carry any cautionary

indicators, these being international product handling symbols and safety warning advice statements

as applicable to the product.

It is the responsibility of the supplier to ensure that all legally required warning, safety information and

markings are applied in accordance with the particular legislation applicable to the product. Products

should also conform to the current UK and European statutory regulations.


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International Handling Symbols

The label size(s) must be relative to the primary pack dimensions so as to provide adequate

information, prior to any movement of the pack. The label must supply all relevant information without

detracting from the pack presentation and must be applicable to the product.


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Additional Warning Labels

These labels are to be used on all packs where applicable to the product or the contents. The label

size(s) must be relative to the primary pack dimension. The position of the label should be placed in

an obvious position where it can easily be seen on the external of the pack. Labels must not detract

from the pack presentation or obscure other labels.

All packs containing glass must be packed in accordance to the generic specifications detailed in this

document


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Plastic Bag and Film Anti-Suffocation Warnings

All plastic bags with an aperture of 190mm or greater and film wrapping, irrespective of the gauge and

vent size must carry anti-suffocation warning notices.

All warnings must be printed as follows

Repeated print at 300mm intervals

Minimum size of 30mm x 70mm

Character font size minimum 10mm high


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Material Identification

The appropriate material identification symbol must be used on all bags, boxes and wraps, in a

position so as not to distract from the warning notice. The correct material number and lettering must

be used in accordance with the material supplied


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Loading

Another important consideration when delivering to Tesco is how you load the container, suitable

loading enables the Tesco Team to handle and unload your products efficiently. Poor loading will lead

to a non-conformance, and your products may be rejected at Goods in.

Ease of Unloading

Products should be easy to unload


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Loading (continued)

Stacking

Always stack the heaviest items at the bottom

Where the case width is the same as the container allowing for a 20cm handling gap, please load

according to the width


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Loading (continued)

Inner Loading Protection

To reduce the risk of damage

in transit, we recommend to fill

the gap requested for ease of

unloading with air bags, see

image below

This is an example of an air fill

bag used in containers


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Weight Restrictions

Product over 20kg should not be stacked above overhead height for all products

EXCEPT for TWO MAN items

Two Man Containers Loading


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Non-conformance at Goods In

It is costly for Tesco and the supplier when products are delivered in a poor condition, they will either

be rejected and/or logged as a non-conformance.

Below are some examples of what a non-conformance looks like.


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Non-conformance at Goods In (continued)


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Non-conformance at Goods In (continued)

Documents

Packaging Standards Supplier Instruction Document · carbon footprint in the chain, and packaging has a part to play. By reducing the overall weight and ensuring minimal size of transit