Category: Sustainability

Symington’s MD Kevin Butterworth talks about rebranding and repackaging Naked ‘The BIG One’ to ‘BIG EAT’, which resulted in an immediate plastic saving of over 50%.

Coupled with the advantage of the Greiner Packaging’s K3^® cardboard-plastic packaging being perfectly recyclable, Naked is the first UK food brand to use the newly improved and more visible tear-tab to make the process of separating the cardboard wrap from the plastic cup as easy as possible.

Symington’s marketing director Kevin Butterworth explained why Naked’s ‘The BIG One’ became ‘BIG EAT’ and why Greiner Packaging’s K3 cardboard-plastic cup delivers on Symington’s journey to full recyclability.

Butterworth said: “Since 2015, Symington’s Naked brand has taken consumer’s taste buds on an adventure in an instant, with authentic Asian flavours. For the last three years, five of our noodle flavours and two of our rice flavours have also been available in a wider, larger format called ‘The BIG One’.

“The brand team identified the opportunity to review our packaging formats during our annual brand planning last year. We did some work to discover who was choosing the larger format, and the consumption occasions. The standard pot was hitting more of a snacking occasion and the large pack was popular for lunch or an evening meal.

“We wanted to know if consumers needed to have the physically bigger pot to justify the occasion and quickly reconciled that they didn’t. This led us to rebranding Naked’s ‘The BIG One’ to ‘BIG EAT’.”

Plastic reduction

Talking about the reduction of plastic when creating the new packaging, Butterworth said: “We discovered that there needed to be a demonstrable difference between the core range and the BIG EAT, but we also learned that consumers were massively favorable towards any format that reduced its plastic.

“Working closely with Greiner Packaging, we carried out a full review of the packaging options.

For the BIG EAT, we reduced the diameter from 116mm to 95mm, to match our core range. This resulted in an immediate plastic saving of over 50%. Coupled with the advantage of the K3 cardboard-plastic packaging being perfectly recyclable, the pack format change has made a significant contribution to our mission to reduce the impact our packaging has on the environment.

“By moving to the new taller cup for BIG EAT, we also slightly reduced the size of the cups for our core range to underline the value differentiation, but without reducing the portion size.

“Throughout the project, the Greiner Packaging team worked closely with us, identifying the most suitable packaging solutions, and pushed the boundaries to create the new pack size which was outside what its existing machinery could produce at that time.

“Many factors contributed to this successful project. We were clear why consumers were choosing the larger pack and for which occasion, and rationalizing the format to match the in-store footprint of our standard product line delivered improved operational efficiency. There is also a significant advantage from the plastic saving and recyclability of Greiner Packaging’s K3. Symington’s is on a journey to full recyclability, so we are currently investigating a range of options to also make the lid recyclable.

UK first for new tear-tab

“The Greiner Packaging K3 pack is perfectly recyclable, as the consumer can easily separate the cardboard wrap from the plastic cup. Naked has been the first food brand in the UK to use Greiner Packaging’s newly improved and more visible tear-tab to make the process as easy as possible. We use the reverse of the wrap not just to show the fill-level, but also to engage Naked fans with more about our brand, and how they can be part of our sustainability journey.

“For Symington’s, consumer research is ongoing, with taste-tracking the top priority. But we also discover more about appeal, relevance, modernity, and other factors. We have learned that our consumers are much more aware about recyclability, so being able to involve them with a strong message about reducing plastic and ensuring the pack is genuinely recyclable is all part of delivering our longer-term CSR commitments particularly around environmental sustainability.”

Source:

https://www.packagingnews.co.uk/design/new-packs/nakeds-big-one-rebrand-big-eat-reduces-plastic

Iceland has launched a series of new packaging trials that will see the supermarket heavily reduce its plastic across nine products.

The nine products will see either plastic-free of heavily reduced packaging replace the current packaging, resulting in a reduction of plastic of 36.6 tonnes.

Frozen vegetables and herbs including garlic, coriander, ginger and chilli will now be packaged in cartons. Iceland’s Soured Cream & Chive Dip and Sweet Chilli Houmous are now packaged in paperboard pots and the supermarket’s frozen 25pk Chicken Dippers and Chicken Popsters are packaged in first to market innovative paper laminate bags.

Iceland’s frozen Easy Peel Wild Red Shrimp will be completely free from plastic with a coated paper bag replacing the old packaging, a truly ground breaking innovation for frozen food.

The new packaging will be trialled in 115 Iceland stores across Cheshire, North Wales and the West Midlands.

Richard Walker, managing director of Iceland, said: “While we are very proud of the progress we have made so far, our journey to becoming plastic free would be much easier if Government set more aggressive, mandatory plastic reduction targets as a framework for business to operate within. Once again, we would also call upon our fellow retailers to make more ambitious commitments to reducing their plastic footprint so we can find solutions that reduce the need to rely on plastic packaging together.”

Source:

https://www.packagingnews.co.uk/news/materials/rigid-plastics/

Mondi has developed a paper-based, aluminium-free packaging material for Unilever’s Colman’s dry Meal Maker and Sauces range that it says can be recycled in existing paper waste streams.

The old unrecyclable multi-material laminate has been replaced, and the previously-used aluminium, as well as what Mondi describes as “unnecessary layers of plastic”, have been eliminated.

This has resulted in a new packaging solution with a paper content of 85% and an ultra-thin functional plastic layer that seals the packaging and provides barrier protection for the food.

Mondi and Unilever’s R&D teams identified this layer as the minimum acceptable protection needed to ensure a long shelf life while maintaining quality and reducing food waste.

The two teams closely collaborated throughout the development process, including during the pandemic when access to production facilities became limited.

The process started with a proof of concept, followed by extensive line trials at both Mondi and Unilever’s R&D pilot plants before scaling up.

On a macro-level, two of Unilever’s key targets are to transform its entire packaging portfolio into technically recyclable, reusable or biodegradable solutions, while halving the amount of plastic it uses by 2025, both of which this new packaging solution aims to address.

Fikerte Woldegiorgis, foods marketing director at Unilever UK&I, says: “We are delighted to partner with Mondi to develop this recyclable paper packaging, becoming the first big brand within the category to do so.

“The new packaging, which uses a paper-base, ensures that shoppers can enjoy the same great tasting product they know and love, and now with the added benefit of being able to recycle the packs.”

Torsten Murra, global head of key accounts, consumer flexibles at Mondi, adds: “MAP2030, Mondi’s action plan for the next 10 years to achieve our ambitious 2030 sustainability commitments, focuses on circular driven packaging and paper solutions, created by empowered people, taking action on climate.

“By working closely with Unilever, we were able to co-create a packaging solution that will deliver on all counts and is recyclable, providing a valuable resource for the circular economy to drive real change towards a more sustainable future.”

Source:

https://packagingeurope.com/mondi-and-unilever-serve-up-paper-based-packaging-for-colmans/

Huhtamaki and Syntegon have today announced a paper-based tablet packaging solution for the pharmaceutical and healthcare industries.

Push Tab paper is made from renewable FSC-certified paper and has been designed with the aim of meeting the stringent safety requirements of regulated pharmaceutical packaging.

The solution also aims to provide customers with a more sustainable alternative to traditional push-through packaging made of thermoformed PVC and aluminium, while helping to reduce environmental impact throughout the value chain.

Push Tab paper tablet contains more than 75% paper-based material sourced from FSC-certified suppliers in Europe. Combining it with advanced barrier coating technology, Huhtamaki says that it makes the pack sealable without compromising its safety, functionality, or protective properties compared to traditional mono PVC (PolyVinyl Chloride) blisters.

A special mechanical treatment reportedly allows consumers to push the tablet through easily without damaging the product inside. The material is further processed and formed with Syntegon’s unique paper shaping technology and machinery.

“We are proud to introduce a new, more sustainable packaging solution for the tablet for the healthcare sector that has high growth potential,” says Fabio Daidone, sales manager for flexible packaging at Huhtamaki.

“European sales of flexible packaging in the Pharmaceuticals category had an estimated value of €1.1 billion in 2020, of which approximately 80% are in blister packaging. We are happy to help our customers respond to opportunities with Push Tab paper, designed for circularity, which presents the first sustainable alternative for this packaging type.”

The German Packaging Institute recognized Push Tab Paper with a 2021 German Packaging Award for sustainability on 27^th July 2021.

Source:

https://packagingeurope.com/huhtamaki-and-syntegon-collaborate-to-launch-paper-based-blister-packs/

Consumers of Coca-Cola in Spain can now pour and pay for drinks themselves as part of a European-first trial of a beverage dispensing system developed by Coca-Cola Europacific Partners (CCEP) and Innovative Tap Solutions (ITS).

ITS’ technology will enable restaurants, cafes, offices, stadiums, and other venues to offer brands in CCEP’s portfolio via self-service taps. Through this system, consumers can refill their own drinks and pay for the quantity served themselves, directly through the tap.

The self-pour, self-pay technology offers consumers a packaging-free delivery method for their drinks, while also aiming to cut down queues, reduce the need for unnecessary contact, and free up serving staff – features that are beneficial as COVID-19 restrictions lift.

ITS, which is new to Europe, will be piloted with CCEP customers Restalia – a Spanish multinational catering group – and Aspro Parks – a company specialising in theme parks, water parks, zoos, and leisure centres.

The first ITS devices have been installed in Restalia’s 100 Montaditos restaurant at Centro Comercial TresAguas shopping centre, located in Madrid, and at Aspro Parks’s Palmitos Park and Aqualand Maspalomas, in Gran Canaria.

This initiative represents a step forward in CCEP’s This is Forward Action on Packaging strategy, which was launched in 2017. CCEP has committed to investing and innovating in refillable and dispensed delivery models with the aim of reducing packaging where it can and eliminating packaging waste, while lowering its carbon footprint as part of its 2040 net-zero ambition.

Craig Twyford, co-founder of CCEP Ventures, the company’s investment arm, comments: “We’re always looking for new and innovative ways for people to enjoy our drinks, thinking beyond the traditional bottle or can, and ITS is a great example of how we’re using technology to help our customers sell and deliver our products in different ways.

“One of the key focus areas for CCEP Ventures is exploring new partnerships and investments to accelerate sustainable packaging innovation and how we can deliver more beverages while using less packaging.

“ITS is an opportunity for us to explore and test new dispensed and packaging-free delivery solutions and, alongside other steps, create a circular economy model that will help us reduce, reuse and recycle our packaging.”

CCEP Ventures invested in ITS in 2020 and plans to co-develop the self-pour, self-pay solution for soft drinks with the goal of bringing new packaging and packaging-free innovations to market for CCEP customers.

Sources:

https://packagingeurope.com/packaging-free-self-serve-beverage-dispensing-system-trialled-by-coca-cola/

Unilever has used new Pulpex technology to develop the first-ever paper-based laundry detergent bottle, which is made of sustainably sourced pulp and designed to be recycled in standard paper waste streams.

Consumers are becoming increasingly aware of the impact of products on the planet and are making purchasing choices based on sustainability factors, including packaging and its sustainability.

With this in mind, Unilever says it is placing high importance on delivering functionally superior products that address environmental issues that people care about.

A prototype paper-based bottle is currently being developed for Unilever’s OMO brand (which is called persil, Skip or breeze, depending on which market it’s sold in), and is set to debut in Brazil by early 2022. The new technology has been developed in partnership with the Pulpex consortium, which is a collaboration between Unilever, Diageo, Pilot Lite, PepsiCo and GSK Consumer Healthcare.

Unilever says the ability to package liquid products in paper-based bottles will be a huge achievement, but before such a bottle hits the shelves, it will be tested against its performance in real-life situations, such as transportation or storage in damp environments.

The paper-based bottles are sprayed inside with a proprietary coating that repels water, enabling the material to hold liquid products like laundry detergent, shampoo and conditioners, which contain surfactants, fragrances and other active ingredients.

While creating recyclable, paper-based packaging without additional plastic layers is a massive challenge, Unilever claims the Pulpex solution offers a “promising way to radically reduce plastic use in line with commitments to a waste-free world”.

“To tackle plastic waste, we need to completely rethink how we design and package products,” says Richard Slater, Unilever’s chief R&D officer.

“This requires a drastic change that can only be achieved through industry-wide collaboration. Pulpex paper bottle technology is an exciting step in the right direction, and we are delighted to be working together to trial this innovation for our products.

“Innovating with alternative materials is a key part of our sustainable packaging strategy and will play an important role in our commitment to halve our use of virgin plastic materials by 2025.”

The company is also piloting the same technology to create paper-based hair care bottles.

The recent development forms part of Unilever’s 2020 commitment to eliminate the use of fossil fuels in its cleaning and laundry products by 2030. Unilever has also committed to halving virgin plastic use by 2025 and aiming for net zero carbon emissions from all its products by 2039.

Source:

https://www.packagingnews.com.au/latest/unilever-creates-world-first-paper-detergent-bottle

Scientists from the University of Edinburgh have devised a novel way of tackling the issue of plastic pollution by using bacteria to transform plastic waste into vanilla flavouring.

The researchers have discovered that the common bacteria E. coli can be deployed to convert post-consumer plastic into vanillin, which is the is the primary component of extracted vanilla beans and is responsible for the characteristic taste and smell of vanilla.

The world’s plastic crisis has seen an urgent need to develop new methods to recycle polyethylene terephthalate (PET), which is widely used for packaging. It is estimated that around 50  million tonnes of PET waste is produced annually, and while PET is recyclable, recycled products can also contribute to plastic pollution. 

To tackle this problem, scientists from the University of Edinburgh used lab engineered E. coli to transform terephthalic acid – a molecule derived from PET – into the high value compound vanillin, via a series of chemical reactions. The team also demonstrated how the technique works by converting a used plastic bottle into vanillin by adding the E. coli to the degraded plastic waste. Vanillin is widely used in the food and cosmetics industries, as well as the formulation of herbicides, antifoaming agents and cleaning products. Global demand for vanillin was in excess of 37,000 tonnes in 2018. 

Researchers say that the vanillin produced would be fit for human consumption but further experimental tests are required.

This is the first example of using a biological system to upcycle plastic waste into a valuable industrial chemical. “The results from our research have major implications for the field of plastic sustainability and demonstrate the power of synthetic biology to address real-world challenges,” says Joanna Sadler, First author and BBSRC Discovery Fellow , School of Biological Sciences, University of Edinburgh.

“Our work challenges the perception of plastic being a problematic waste and instead demonstrates its use as a new carbon resource from which high value products can be obtained,” adds Dr Stephen Wallace, Principle Investigator and UKRI Future Leaders Fellow, School of Biological Sciences, University of Edinburgh. 

“Using microbes to turn waste plastics, which are harmful to the environment, into an important commodity and platform molecule with broad applications in cosmetics and food is a beautiful demonstration of green chemistry, comments Dr Ellis Crawford. Publishing Editor at the Royal Society of Chemistry. 

The study, published in Green Chemistry lays the foundation for further studies to maximize vanillin production towards industrially relevant levels.

Source:

https://packagingeurope.com/from-plastic-waste-to-vanilla-flavouring/

Lecta has presented EraCup Natural, a paper-based solution for single-use cups that the company says is recyclable, biodegradeble and polyethylene-free. 

EraCup Natural is the first product in Lecta’s new range of functional papers for “nature-friendly packaging”. The new EraCup Natural solution is based on a proprietary process that is both polyethylene and bioplastic free. Its composition allows the paper to be recycled in standard paper recycling circuits after having been converted and used.

EraCup Natural is a SBB paperboard manufactured with pulp from certified sources, available in substances from 170 g/m2 up to 380 g/m2. It has an uncoated outer face, with a smooth, natural finish suitable for high-quality flexography and offset printing. The inside is covered with a sealable aqueous dispersion that guarantees the manufacture of liquid-tight paper cups. In addition, this paper-based solution allows for energy savings since cups made with EraCup Natural require lower sealing temperatures compared to those manufactured with current polyethylene materials. 

The company says that the cup’s properties make it ideal for hot and cold beverage cups as well as on-the-go disposable containers.

Source:

https://packagingeurope.com/lecta-launches-polyethylene-fre-eracup-natural/

In the second of a series of articles looking at ThePackHub’s Global Packaging Trends Compendium, Paul Jenkins, Managing Director, ThePackHub, takes a look at the subject of refills. 

The Global Packaging Trends Compendium 2021 details more than 550 packaging innovations and is grouped into nine trends. ‘Refill Revolution’ is one of the trend areas that is exhibiting strong growth. Despite potential disruption from the COVID-19 pandemic, reusable and refillable packaging examples have increased in occurrence, notably over the last 18 months as brands, retailers and suppliers look at ways of reducing single-use and difficult to recycle packaging. Sectors such as dry food, household products and personal care are leading the way by making the most initial ground to transition to refillable and reusable packaging models.

The majority of the in-store examples coming to market are at the small trial and pilot stage, with refillable packaging systems set up in a handful of test stores. Major retail chains are testing the water with a small number of initiatives in outlets. However, cosmetics, skincare and perfume retailer The Body Shop is bucking this trend and scaling up their trial operations.

Refillable scheme starts global roll out

Following successful trials in two of its concept stores, The Body Shop is rolling out its refill and recycle scheme across the globe. The initial trial, started in 2019, was launched in Bond Street, London, and Vancouver’s Pacific Centre store. The extended launch will start in France, across 47 stores, and will extend to 400 stores worldwide by the end of 2021. The Body Shop plans to have refill stations in all of its stores by 2026. The scheme works by shoppers being given a 250ml aluminium bottle, then choosing from a selection of products, including shower gels, shampoos, conditioners and soaps. Once the product has been used, the customer cleans the bottle themselves and returns it to the store for a refill. The number of refill stations will vary depending on the size of the store but is expected to be between six and 12 per outlet.

Gable-top carton refill pack for soap launched 

Norwegian home and personal care manufacturer Orkla has collaborated with Elopak to produce a sustainable refill pack for its Klar laundry detergent and liquid soap products. The new board-based carton, called D-PAK, is a move by Orkla to help consumers reduce the amount of plastic generated in the waste stream. The gable-top carton is made from renewable materials and is said to be suitable for recycling with other board products such as milk cartons and newspapers. A trial has been conducted with selected retailers and online purchasers. Consumer feedback has been positive, with reports that refilling is easy and convenient. Consumers need to pour from the carton into the original plastic container. It is said that the new pack is more efficient through the supply chain, as it saves weight and is also more cost-effective by volume. A label over the cap is added to alert the consumer that the pack’s contents are not for consumption. 

Return and refill scheme aims to reduce carbon footprint

Upcircle, a ‘by-product’ sustainable skincare brand based in London, is launching a new return and refill scheme to help reduce its carbon footprint. The company repurposes waste materials, such as coffee grounds from London coffee shops along with other waste products such as fruit stones, argan, olives, juice and tea. Ninety-nine per cent of the company’s current packaging is already plastic-free, being made from easily recycled board, glass and aluminium and now the remaining 1% can now also be recycled. Customers will be able to return their cleaned, empty packaging free of charge, which will then be sterilized, refilled and returned to customers. As part of the scheme, the shopper will receive a 20% discount on the original price. Upcircle also has an in-store set up where customers can bring in their packs to be refilled from bulk containers. 

Reusable cup trial starts coffee chain trial

Coffee shop heavyweights Starbucks are trialling a new reusable cup programme called ‘Borrow a Cup’ in five Seattle stores for two months. The aim is to reduce single-use cup waste. The customer requests a reusable cup and pays a $1 deposit. When the drink is finished, it can then be scanned at a participating store’s collection point, and once the cup’s return has been confirmed the $1 is refunded along with 10 bonus points that are added to the customer’s account. The cups are then taken away and commercially cleaned and sanitized. The cups are ready for reuse within 48 hours. The expected number of reuses for each cup is 30 times before they are recycled. The initiative is part of Starbucks’ aim to reduce waste by 50% by 2030.

The Refill Revolution trend is anticipated to maintain its growth trajectory. Brands and retailers will continue to develop refillable and reusable solutions to meet their sustainability objectives as the sector becomes more normalized.

The 2021 Global Packaging Trends Compendium comprises nine new packaging trends. It features a comprehensive assessment of more than 550 packaging innovations. It also includes the interviews of 16 industry experts from around the world, featuring packaging experts from the likes of Mars Wrigley, Mondelez, Ocado, as well as Tim Sykes, Brand Director at Packaging Europe.

More information here: https://www.thepackhub.com/services/global-packaging-trends-compendium-2021/

Source:

https://packagingeurope.com/Packaging-Trend-Focus-2021-refill-landscape/