Sustainable Packaging Supplement | Beverage Innovation by FoodBev Media Ltd

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2010 supplement BEVERAGE innovation

Sustainable Packaging 漏 beverage innovation 2010. Reproduced with the kind permission of FoodBev Media - www.foodbev.com For details about syndication and licensing please contact the marketing team on 01225 327890.

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January 路 February 2010

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Planet and pocket - sustainable packaging to make you smile

o consumers care about packaging? Or is cost their only priority? Guilt trip or recycled rubbish - the choice is simple and the industry is leading the way. Packaging choice is here to stay and carbon rating (measuring carbon emissions) across all types of packaging is underway, both in terms of production, how efficient it is to transport and how easy it is to recycle. In this supplement on sustainable packaging, I am questioning those packaging in glass, cans, cartons, biopolymers and PET to uncover latest moves towards a more sustainable future. Claire Phoenix Editor

4 6 7 8 9 10 11 12 14 15

Jane Bickerstaffe speaks on behalf of INCPEN. Affordable green options at EcoPack.

Rob Miles of Ball Packaging underlines green advantages of can recycling.

Latest figures on recycling steel packaging in Europe from APEAL.

O-I on the sustainable heritage of glass. Rexam predicts the future for canmakers. Naked Juice reNEWabottle. Tetra Pak, Elopak and SIG aim for full traceability. Eco award for Graphic Packaging. John Williams of the NNFCC on biopolymers.

Coca-Cola’s recyclable Plantbottle. Coca-Cola Hellenic in Austria meeting social responsibility targets. Sidel and Husky working with recycled PET. Eastman Chemical on copolyester films.

Matthias Gernuber on KHS making strides in safe filling and evironmental responsibility.

Tetra Pak driving growth in carton recycling. CSI sustainability with short height and lightweight closures.

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INCPEN and Ecopack share their thoughts

Jane Bickerstaffe of INCPEN

anufacturers and retailers are constantly seeking to improve all types of packaging and develop new ones to help reduce the environmental and social impacts of delivering products to consumers. INCPEN members all have a long recycling track record. By offering consumers packaging options that fit their needs, the industry can help reduce wastage and avoid unnecessary energy use. I believe that widening the availability of different pack sizes should be an industry priority because it has more potential to benefit the environment than ‘green’ materials. What in your view has been the greatest development in sustainable packaging within the last year or so? INCPEN does not think there is such a thing as ‘green’ or ‘sustainable’ packaging. We believe that all types of packaging can be designed to be more sustainable and we know that manufacturers and retailers that belong to INCPEN have made all sorts of improvements in the last few years including lightweighting containers, improving shelf life of products, incorporating recycled content where that makes environmental and economic sense and offering a wider range of portion sizes. What more do you think can be achieved? Continuous improvement to existing packs, trying new materials, including polymers made from renewable resources, making some packs easier to open, making instructions easier to read and helping ensure that packaging and products help consumers live more sustainable lifestyles. How do you view rPET, cans, cartons, pouches and bioplastics? All these materials have pros and cons - none has a monopoly of environmental virtues. In general all packaging protects far more resources than it uses and prevents far more waste than it generates. The important

factor in choosing packaging is how well it protects its contents, not what it is made from. What are the big issues in sustainable packaging now? The biggest issue is explaining to the public and politicians that overall packaging has a net positive environmental impact, though there are a few exceptions. INCPEN has campaigned for years against excessive use of packaging. There is always room for improvement but companies are already doing lots and there are a number of drivers in place the European Packaging Directive, CSR, INCPEN’s Responsible Packaging Code, Best Practice Guides, Green Supply Chain initiatives - to continue to push them in the right direction. There is no need for more regulation or drivers. What advice would you give to beverage manufacturers planning their next packaging? Overall advice would be to make sure the product survives the stresses and strains of distribution and handling. After that, identify where the big environmental impact occurs for each type of beverage and try to reduce it. For example, in contrast to milk, energy used for packaging for carbonated soft drinks is bigger than energy used in production of the drink so it is important that manufacturers keep informed about all new packaging materials and technologies. However, the materials used for drinks packaging typically have a high scrap value and it is no coincidence that drinks containers are the most widely recycled type of packaging. Over 60% are recycled in the UK which significantly offsets their energy use.

Affordable green options at Ecopack

copack exhibition by easyFairs is taking place at Birmingham’s NEC on 24 and 25 February 2010 and is free to attend. It is the only UK show dedicated to sustainable packaging; recyclable, reusable and lightweight materials; low waste packaging design; and low energy manufacturing techniques. And co-located with three other packaging events it will play host to an array of exhibitors, a packed learnShops programme and will be attended by major retail buyers, brand managers, product developers and packaging specifiers working in the UK. So it seemed fitting to ask some of the companies exhibiting how they see the sustainable packaging debate playing out - and how they are responding. Firstly, what is your view of sustainable packaging? “Sustainable packaging is an absolute necessity considering the world’s current environmental issues,” says Louise Aplin, Marketing Manager from bpi.films. James Woollard, (top right) Managing Director of Polythene UK agrees: “Sustainable packaging is the future for the packaging industry. Choosing the green option is not only the ‘feel-good’ thing to do these days, it’s the thing that we have to do in order to help save the environment. Sustainable packaging is vital to achieving this.”

job the consumer throws them away and consequently sees them as disposable, as part of the waste stream and as something that’s detrimental to the environment. The reality however isn’t quite so clear cut.

Polythene packaging “Polythene packaging for instance might not be widely regarded as green but its light weight and high strength actually prevents bulkier materials being used which could lead to an increase in transport emissions. Likewise, its effectiveness helps to reduce other forms of waste such as that from damaged or spoiled goods - food rotting in landfill gives off methane which

However Louise Aplin adds that consumers need to be educated more about packaging’s benefits: “Once our products have done their

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is 20 times more effective as a greenhouse gas than CO2.” “Many plastic films can be recycled again and again. Even when packaging plastics can’t be recycled, they can still be put to good use rather than sent to landfill.”

Closed loop resource Nick Cliffe, Marketing Director of Closed Loop Recycling agrees people need to see packaging waste in a different light: “Good packaging already plays a significant role in minimising both food waste and the carbon cost of transporting and storing food. Packaging waste needs to be seen as a resource, not a problem.” Jayson Clark, a Director at CFN Packaging in Skegness, Lincolnshire believes there are some practical barriers which the UK needs to tackle: “Sustainable packaging has an important role to play in helping the packaging industry to reduce the environmental impact of packaging. However, given the recent economic conditions sustainable packaging products must remain competitive to be seen by the consumer as a

viable alternative. The UK is still held back by a generally poor recycling system which hinders the objectives of the loop cycles in having sustainable packaging.” Nick Cliffe of Closed Loop Recycling agrees: “It will become increasingly important for packaging to be considered at all stages in its life - with all parties working together to ensure a positive environmental outcome - starting with the manufacturer and the retailer, but including the waste companies and recyclers to really close the loop effectively.” Who do you see as driving this growth sector - consumers, retailers, packaging designers, or manufacturers? Louise Aplin from bpi.films sees the pressure as coming from a number of quarters: “The growth in demand for greener packaging is being driven by everyone from those in government to the man on the street. Legislation is certainly fanning the winds of change, but there’s no question that social conscience is playing a major part as well.” Zena Bergmann, from Innovia Films agrees: “We’re committed to providing innovative solutions to meet our customers’ requirements and sustainable packaging is increasingly becoming a part of this, with demand driven by both end users and consumers.” It is important to help price sensitive consumers to go down the sustainable route argues Polythene UK’s James Woollard: “With the economic climate still as it is, low cost products will always attract the consumer. Therefore it is the role of the retailers, packaging designers and the manufacturers to ensure that sustainable packaging becomes not only a ‘green’ option, but an affordable option. We all have a role to play, and we all must work together. It’s about educating and delivering.”

Nick Cliffe of Closed Loop Recycling sees things shifting right across the supply chain: “Consumers increasingly demand packaging with the lowest possible environmental impact, retailers are adjusting their procurement strategy accordingly, designers are thinking of sustainability across all new packaging products and manufacturers are also playing their part.” For Jayson Clark of CFN Packaging, retailers are creating the most impetus: “Growth in this area is mostly being driven by retailers who want to improve their green credentials and market share by fulfilling the demand for greener products at competitive prices.” What are your key sustainable packaging developments? For bpi.films, a key development is its Nov8 shrink film, Louise Aplin again: “What makes Nov8 a greener choice is its production using solvent free technology, which eliminates ozone damaging Volatile Organic Compounds (VOCs) from the process, and its down gauged nature. It has been engineered to offer all the performance of a conventional shrink film but from a considerably thinner film thickness meaning users employ less film by weight and so create less packaging waste. This waste can be reprocessed rather than sent to landfill as Nov8 is 100% recyclable.” Polythene UK has a new compostable ‘Polycomp’ bag which it is launching at easyFairs Ecopak. According to James Woollard the biopolymers used in the bags consist mainly of starch and biodegrade fully within just ten days. The bags are certified as fully biodegradable and compostable according to the European norm EN13432. “The biopolymer used in our new compostable bags totally

Jayson Clark transforms into biomass with CO2 + H2O or CH4 within a few days in a composting site.” CFN Packaging’s Jayson Clark adds: “We have installed a new recycle system which recycles approx 70% of our production waste as well as other trade waste. We have improved energy efficiency in the factory by replacing equipment with more energy efficient options. We have promoted our degradable polythene additive Biothene and have seen a 250% increase in its sales over the year. It is made and sold in the UK so avoids transportation impacts on the environment and it uses the same amount of energy in manufacture as non-degradable packaging.”

Biodegradeable film A key development from Innovia Films is NatureFlex. It has been chosen by Twinings to wrap one of its major tea products, Everyday. NatureFlex NM is a unique cellulose based film, manufactured from renewable wood pulp and metallised inhouse. It is the only metallised biodegradable film suitable for home composting because the level of metal is so small - less than 0.02% - which slows the film’s degradation by a matter of days but does not interfere with its biodegradability in any other way.

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Ball Packaging Europe underlines green advantages of cans Where do you see can manufacture currently in regard to sustainable packaging? For us sustainability has become one of the most important topics. The beverage producers, as well as retailers, are quite rightly setting a very demanding environmental profile for all packaging. However, the beverage can has an excellent ‘green’ performance. It has developed in recent years into the most environmentally friendly beverage container. Since the 1970s the weight of the beverage can has been reduced by some 50%. They are today the most lightweight of all drinks packaging. And with regard to recycling we can say that the can is the most recycled drinks pack in the world. Across Europe about 70% of all beverages cans are recycled and for every can recycled an equal amount of raw material is displaced. As fewer emissions are produced using recycled material, it follows that the higher the recycling rate the lower the CO2 emissions. Recycling cuts greenhouse gas emissions by 75% for steel and 95% for aluminium - and that is for each can recycled. Another ‘green’ advantage of the can compared to other drinks packaging is its stackability. This unique

attribute makes it extremely efficient for transport and storage. In the case of beverage cans, the amount of CO2 emitted during transport is on average 57% lower than that of beverage packaging made of glass or PET. These were the findings of a model calculation on the topic of transporting beverages in containers which was developed in 2008 by Incept, the British consulting and research company. What moves have been made in the industry recently to improve this position? We as can manufacturers are co-operating closely with all partners across the whole supply chain to continuously improve environmental performance. We are working on projects to make our cans lighter and to use less material in production. Here the expertise of our metal suppliers is needed as well the agreement and support of our customers. In 2008 we launched a programme to encourage the recycling of drinks cans in the work place. ‘Every Can Counts’ offers British employers the opportunity to promote recycling at work by providing access to a collection service and offering communications resources designed to encourage employees. Ball Packaging Europe is a leading member of this initiative which is funded mainly by the associations alupro,

the UK Canmakers and Beverage Can Makers Europe (BCME). The campaign is also being supported by the non-profit organisation WRAP (Waste & Resources Action Programme) which is funded by the government and by the British Minister for Farming and the Environment. In which sectors of the beverage industry are you seeing most sustainable packaging growth? In sports or energy drinks, sodas or another drinks category? Is this primarily for cost or environmental reasons? At the moment the market for beverage cans in Europe is relatively flat, due to the difficult macroeconomic environment. However, our industry is not suffering as much as other industries. In the near future the market will start to grow again. The can will gain market share from glass especially in the beer segment, because the can is light, more convenient for the consumer and more beneficial for the environment. It keeps the content fresh for a longer time. Also, the can is unbreakable and better suited for big events such as festivals or for the on-thego consumption. In the energy drink segment can sales have doubled in the last five years in Western Europe and more than quintupled in Eastern Europe.

Picture: Ball Packaging Europe

What are the big issues right now for Ball in terms of sustainability? At Ball we are continuously improving our production processes. From minimising waste and spoilage to the best use of materials, the exclusive use of water based varnishes, thermal treatment of waste air and the saving of water by using special washing processes. In 2009 alone, Ball Packaging Europe invested a total of more than €4 million in environment protection measures at its European facilities. Our aim is to reduce energy consumption by a further 5% at our plants

Rob Miles, Vice President Sales and Marketing in this year alone, for instance by modernising our equipment or through systematic energy management. We are now working on our second sustainability report which is scheduled to be published mid 2010. How do you see things changing over the next five years? The interest of consumers in the sustainable aspects of consumer goods is an ongoing trend. As a result, demand for environmentally friendly beverage cans will grow - not only in the established markets in Europe but also in Asia and Africa. But it won’t be sufficient to just provide environmentally friendly goods to the market - we have to tell the story as well: from where we get our raw materials, what we do to improve our production to how we ensure that our used products are returned to the recycling loop. The consumer will become more demanding in terms of increasingly tailor made individualised products and an individualised communications approach. There will be a diverse landscape of special interest groups in which trends will change more rapidly. Therefore, we are focusing our efforts to increase the speed to market of our innovations and develop forward looking technologies such as digital printing with which it is possible to print individual designs on cans and to find a creative approach to address specific target groups.

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Steel for packaging: Europe’s recycling leader

he latest figures from APEAL (the Association of European Producers of Steel for Packaging) show that 70% of steel packaging is recycled in Europe. This represents over 2.5 million tonnes of food and drinks cans and other steel containers being recycled in 2008, saving 3.9 million tonnes of CO2. According to the latest available data, this places recycling rates for steel above those of other packaging materials such as plastic, beverage cartons and glass (29%, 33% and 62% respectively). recycling plant, producing steel of virgin quality while saving valuable resources. Complementing this is a network of well established routes for collection and recovery of steel cans across Europe which has helped to ensure recycling excellence.

Unlike other materials, steel loses none of its strength or inherent qualities, no matter how many times it is recycled.

By integrating recycled steel into the manufacturing process the industry achieves energy savings of 70% and lowers its output of CO2. In fact, each item of recycled steel packaging saves one and a half times its weight of CO2. So the more steel is recycled, the more CO2 emissions are reduced.

100% 90% 80% 62% 60% 50% 40%

Another reason for steel’s continued recycling success is that the recycling process is embedded into steel production. Put simply: to make steel, you have to use recycled steel. This means that every steel plant is a

33%

29%

30% 20% 10% 0%

Plastics

Beverage cartons

Glass

Steel

Source: Industry experts - Association of European Producers of Steel for Packaging (APEAL) - European Glass Packaging Federation (FEVE) (figures for glass relate to year 2007) - The Alliance for Beverage Cartons & the Environment (ACE) - PlasticsEurope

Saving energy and carbon

Made to be recycled

70%

70% Recycling rate (%)

Steel’s performance owes much to its unique material properties. The fact that steel is magnetic makes it the easiest and most cost effective material to sort and recover. When household waste is recycled, these magnetic properties enable steel packaging to be easily separated from cartons, plastic and other packaging materials.

Recycling of Main Packaging Materials in Europe (2008)

that by recycling we can make an important contribution to reducing CO2 emissions,” says Guillaume de Formanoir, President of APEAL.

grow throughout Europe rising by 1.4% from the 2007 total. Belgium was once again Europe’s recycling champion where 93% of steel packaging was recycled. Germany, Luxembourg and the Netherlands follow closely behind, recycling over 87% of their steel containers.

Improved recycling performance across the board

“Once again steel is setting the standard for recycling across Europe and demonstrating

In 2008, the recycling rate for steel packaging continued to

Recycling of Steel Packaging in Europe (2008) 100% 93%

90%

EU27 (+Norway & Switzerland): 70.4%

80%

71%

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76% 77%

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83% 80% 82%

62% 63%

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Belgium, The Netherlands, Finland, Latvia, Slovenia, Lithuania, Estonia, Malta, Bulgaria, Romania: Metal packaging recycling rate (steel and aluminium) Finland, Denmark, Greece, Poland, Slovenia, Lithuania, Romania (2007 - latest official data) Source: Official Member States figures and PRO’s/APEAL members

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O-I and Rexam

O-I offers sustainability with design appeal

Rexam predicts the future for canmakers

010 trends and predictions for the beverage can industry: by John Revess for Beverage Can Makers Europe. • 2010 will definitely be a better year for the beverage can • In 2009, economic conditions shocked the entire supply chain forcing the industry to make sudden readjustments. Now these changes have been made, the packaging industry is entering a period of stability

wens-Illinois providing glass packaging with a sustainable heritage for premium beverages.

For over 3,000 years, glass has set the benchmark for sustainable packaging. Made from naturally abundant raw materials and endlessly recyclable, glass packaging has never been a ‘me too’ product; it has personality and provokes an emotional response. Many European consumers have come to enjoy their beverages in what is widely acknowledged as the ultimate in low carbon packaging - returnable glass bottles, which can be reused on filling lines up to 50 times before being melted down to create bottles. Matthias Warneke, NAB Marketing Manager for the world’s leading glassmaker O-I said: “High quality retail and Horeca brands make extensive use of recyclable, one-trip glass, which is the most widely recycled material across the continent. When kept in a closed loop system, each glass bottle recycled saves enough energy to power a television set for 20 minutes.” Sustainability also includes ensuring that food and drink does not go to waste. The structure of glass makes it an invincible barrier for gases, liquids and micro-organisms,

allowing glass containers to safeguard their contents from external contamination. The material is chemically inert and homogeneous; it preserves the authentic taste and aroma of beverages for a long period. Douglas Lamont, Managing Director of This Water said: “We make things as simply and naturally as possible and believe that, if you put the best ingredients in, you will get the best taste out. O-I has delivered a lightweight bottle with bespoke design that helps reinforce our premium positioning in the on-trade.”

• In terms of the beverage can, it is still an everyday, convenient and economical packaging choice • There is no end to our increasingly time-poor lifestyles where the consumer is constantly on the go. The can is therefore a perfect fit for this lifestyle, being easy to carry, light and unbreakable • Post Copenhagen, the world is focused more than ever on carbon efficiency • These issues are beginning to move beyond the domain

of special interest groups and policy makers to become a mainstream consumer concern

• Thanks to the can’s light weight and its 100% recyclability, the beverage can market is in a good position to compete • Society is moving beyond green washing and political correctness. But it will be a gradual education process for the consumer • The beverage can is in a good position to inform and educate due to its large surface area - ideal for getting the simple recycling message across • Consumer actions are starting to be motivated by what will truly make a difference to the environment • It makes both environmental and economic sense to recycle cans, so metal packaging is well placed to make a genuine contribution.

Simon Speers of Bottlegreen said: “Our drinks are known for their purity, natural ingredients and stunning taste. As a packaging material, glass best reflects these brand values and has a very high recycled content. The cordial range has been a great success since we rebranded the 500ml bottles.” Veen Managing Director, Tomi Grönfors said: “No other material protects like glass; it is totally inert, so never affects the taste of our water in any way. And is 100% recyclable to make brand new containers time after time.”

John Revess joined Rexam in June 2005. He now holds the position of Vice President of Marketing and Environmental Affairs at Rexam Beverage Can Europe and works closely with the BCME to better understand and address industry environmental issues.

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Naked message in a reNEWabottle by Chris Malnar, Senior Brand Manager with Naked Juice How has Naked moved to achieve more sustainable packaging? As a part of our ongoing commitment to quality and sustainability in everything we do, we were very excited to announce this past July that Naked Juice has become the first nationally distributed beverage brand in the US to transition to a 100% postconsumer recycled PET bottle. The Naked reNEWabottle is a bottle made from other bottles and truly embodies our commitment to creating a more earth conscious juice. Our mantra is, reduce, reuse, recycle . . . reincarnate! Throughout the product lifestyle - from sustainable sourcing to sustainable manufacturing Naked Juice strives to reduce its environmental footprint, offering consumers maximum taste and minimum impact. How long did the whole process take and is it now being used across all Naked products? We started by converting all of our 32oz bottles in July 2009 and expect to have all bottles in our product line transitioned by the end of 2010; at which point the Naked reNEWabottle will reduce virgin plastic consumption by 8.1 million lb every year! What was the thinking behind the move and how do you see it benefiting consumers? We believe our investments in sustainability will yield both longterm business benefits of consumer loyalty and environmental benefits of a reduced impact on our planet. Consumers know that by drinking Naked Juice, they are not only doing something good for their bodies by choosing an all natural, 100% juice with no added sugars or preservatives, but are also making a conscientious choice for the environment.

Our target consumers are demanding a more earth friendly juice and they are responding very positively to our efforts. As soon as we announced the Naked reNEWabottle, we received a flood of positive feedback from consumers via Facebook, Twitter, their blogs and our customer service line. Naked Juice lovers have been extremely excited about the transition! To celebrate the Naked reNEWabottle, we also launched an online charity initiative in September 2009, which asked people across America to join the eco-revolution by simply passing on a ‘Naked Message in a Bottle’. For every bottle passed (up to 400,000), Naked Juice is donating five cents (up to $20,000) to Keep America Beautiful - the nation’s largest volunteer based community action and education organisation - and its recycling education initiatives. Some additional sustainable steps we’ve made include: • In April, Naked Juice announced that it became the first US based juice company to team up with the Rainforest Alliance for sustainable fruit procurement. The Rainforest Alliance Certified seal is included on all Naked Juice products containing bananas, which are found in 80% of Naked Juice products. • Late last year, we also announced that we are moving to a new facility, designed to meet the criteria for LEED certification. This new plant reflects Naked Juice’s commitment to making superior products in environmentally responsible buildings. What are the big issues on sustainable packaging for Naked right now and how do you see things changing in this area over the next few years?

is a significant one that we had to work very hard to achieve but that we feel is certainly worth it. One issue we faced was supply, which is still limited in the US as the rate of recycling is small compared to many European countries. The lack of recycling infrastructure to collect bottles means that there

is less recycled plastic available for use. However, we feel that as consumers become more educated about recycling, this supply will increase. Naked Juice will continue to help educate consumers on the importance of recycling and environmental responsibility.

Cartons aiming for full traceability Significant progress has been made by ACE beverage carton companies towards achieving full traceability certification of wood used in cartons and of the factories that produce them worldwide. Certified or controlled fibres purchased by Tetra Pak, Elopak and SIG Combibloc which together make up up four fifths of the global drinks carton market rose from 47% in 2007 to 77% in 2008. This is the conclusion of ProForest an independent verifier of natural resource management in its second annual report on the chain of custody commitment made by the three companies in 2007. “These identified advances are very good news,” commented ACE Director General Christian Verschueren. The aim is to acheive 100% chain of custody certification by 2015.

The transition to 100% postconsumer recycled PET bottles

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Eco award for Graphic Packaging International

ver the last 12 months, Graphic Packaging International, one of the largest producers of folding cartons, has developed a range of ecologically-viable, packaging solutions. The Cap-it pack, provides a nature based, environmentally friendly and completely recyclable paperboard alternative to traditional Hi-cone and shrink wrap packaging. Cap-it has already received an award for its eco-friendly impact on product differentiation, merchandising and sustainability. As always, innovative package design is supported by Graphic Packaging’s proven machinery portfolio, with equipment available to run a wide range of PET bottle sizes and package formats. Of particular interest for high volume products is Graphic Packaging’s new Nested Wrap for

cans. This innovative design runs at high speed on conventional packaging machines, with a construction that is materialefficient and attractive, highlighting primary container graphics. Other new minimum fibre packages include a family of can and bottle clips and a two-piece, fully enclosed carton for bottles designed to allow the use of reduced thickness, low fibre packages. These are all able to run on existing equipment. Keith Brimble, the company’s International Marketing Director for Europe, Middle East and Africa commented: “Graphic Packaging

International has a clearly stated commitment to develop packaging solutions that improve the world in which we live. We start with an advantage because our packages are made from paperboard, which is a nature based, sustainable, recyclable, renewable, and ecologically friendly raw material. However, in addition to the inbuilt advantages offered by this medium, we have also been working hard to minimise the fibre content in our packs. This works from an environmental standpoint, and allows us to offer customers efficient and

very competitively priced packages.” Today’s consumers and brand owners are focusing on sustainability of innovation in both products and packaging. Graphic Packaging International’s commitment to this philosophy is reflected in the company’s vision statement, “We provide packaging solutions that improve the world in which we live.”

Renewable materials, renewable carbon

ohn Williams, Polymers and Materials Manager for the NNFCC (the UK’s National Non Food Crops Centre).

The average petrochemical based polymer is made from fossil carbon that was taken from the atmosphere by a living creature millions of years ago. Not only is this a finite reserve of carbon, but if it finds its way into the atmosphere by biodegradation or incineration it will contribute to climate change. Biopolymers, however, are made from renewable carbon. Plants sequester CO2 from the atmosphere as they grow and this carbon forms the basis of bio based products.

However this carbon is subsequently released into the atmosphere by biodegradation, anaerobic digestion, or energy from waste. It will not cause a net increase in greenhouse gases as it will be absorbed by another growing plant. This rapidly renewing carbon cycle is one of the key environmental benefits of renewable materials. The amount of carbon that comes from a renewable source rather than a finite petrochemical source can actually be measured, as biomass and fossil material contain different types of carbon atom called isotopes. The US is raising public awareness and encouraging the use of bio based materials through the USDA BioPreferred Voluntary Labelling scheme. Participants in the scheme can submit their products for testing to prove the bio based content. They can use on-product label and marketing.

Bio based but durable Bio based doesn’t have to mean biodegradable. Now there are bio based durables such as polyethylene derived from sugar cane. Based on recent company announcements the production capacity of bio based plastics is projected to increase from 360,000 tonnes in 2007 to about 2.3 million tonnes by 2013. This corresponds to an annual growth of 37%.

Non-biodegradable bioplastics such as polyethylene, polyvinyl chloride and polypropylene will be the primary demand driver. And demand for nonbiodegradable plant based plastics will increase from just 23,000 tonnes in 2008 to nearly 600,000 tonnes in 2013. This will be strengthened by the European Commission’s Initiative for Bio Based Products, which will foster an innovation friendly market. Meet us at Ecopack stand 458, in Birmingham, UK.

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100% recyclable plant bottle

he Coca-Cola Company has announced that beverages in its innovative PlantBottle packaging are beginning to arrive on shelves in select markets around the world, initiating the company’s journey towards a goal of producing two billion of the special PET plastic bottles by the end of 2010. PlantBottle PET plastic bottles are made partially from plants, which reduces the company’s dependence on a non-renewable resource: petroleum. Other benefits are that it’s 100% recyclable, and preliminary research indicates that from the growing of the plant materials through to the production of the resin, the carbon footprint for the PlantBottle packaging is smaller than for bottles made with traditional PET.

“The PlantBottle is precisely the kind of innovation that demonstrates how businesses can help address climate change and reduce stress on our precious natural resources,” said Kate Krebs, Director of Sustainable Resources for The Climate Group. “While CocaCola is just beginning to bring its plant based PET plastic into the mix, this is a revolutionary solution that has the potential for long term, meaningful benefits.”

“Today, we are taking a major step along our sustainable packaging journey as The Coca-Cola Company becomes the first to market with a recyclable PET plastic bottle made partially from plants,” said Muhtar Kent, Chairman and CEO, The Coca-Cola Company. “From Coke brands in Copenhagen to Dasani water in the Western United States, we are starting to roll out the first generation of the bottle of the future.”

PlantBottle packaging is currently made through a process that turns sugar cane and molasses, a by-product of sugar production, into a key component for PET plastic. The sugar cane being used comes from predominantly rain fed crops that were processed into ethanol, not refined sugar. Ultimately, the company’s goal is to use non-food, plant based waste, such as wood chips or wheat stalks, to produce recyclable PET plastic bottles.

Throughout Denmark, CocaCola, Coca-Cola Light and Coca-Cola Zero in 500ml and 2 litre sizes are now available in the PlantBottle packaging. A variety of products, including Coca-Cola, Sprite, Fresca and Dasani, will be in Western Canada in the PlantBottle beginning in December, and for the Vancouver 2010 Winter Olympic Games.

“Coca-Cola is currently sourcing raw materials for its PlantBottle from suppliers in Brazil, where third parties have verified that best-inclass agricultural practices are the norm,” said Dr Jason Clay, Senior Vice President of market transformation for WWF. “Preserving natural resources through sustainable agriculture is essential for businesses like Coca-Cola as they search for ways to alleviate environmental challenges.”

For select markets in the Western US - including Seattle, San Francisco and Los Angeles - PlantBottle packaging will be used for sparkling brands and Dasani in several sizes, starting in January. Future launches are being planned in other markets, including Brazil, Japan and Mexico, and for China’s Shanghai Expo in 2010.

PlantBottle packaging. The combined plant based and recycled content makes up 65% of the material, with 50% coming from recycled material and 15% from plant based material. For the PlantBottle packaging in the US and Canada, up to 30% of the content in the PET plastic comes from plants. “While the PlantBottle introduction and market launch put The Coca-Cola Company on the forefront of bio based packaging innovation, we are continuing to strive to make an even better bottle,” said Scott Vitters, Director of Sustainable Packaging, The Coca-Cola Company.

“Our vision is to continue innovating to achieve a bottle that is made with 100% plant waste material while remaining completely recyclable.”

Coca-Cola Hellenic Austria meeting social responsibility targets Coca-Cola Hellenic Austria has taken a variety of measures to live up to its social responsibility in protecting the environment. Coca-Cola Hellenic Austria’s operations are certified according to the globally recognised environmental management standard ISO 14001 and uses latest technologies to reduce water and energy consumption in all production and recycling. • Coca-Cola Hellenic Austria played a crucial role in the development of the ARA Altstoff Recycling Austria collection system for PET bottles. • The company became a founding member of PET to PET Recycling GmbH through transforming PET bottles into PET flakes, which are mixed with other material and made into new PET bottles. Up to 20,000 tonnes of PET bottles are recycled every year. • During UEFA Euro 2008, about 500 cooling devices were replaced by eco coolers. These cooling devices do not use fluorinated hydrocarbon (HFC) as a cooling agent. The effort was honoured by the Ministry of Life with the ‘Grüner Ball’ award.

While the bio based component can account for up to 30% of the resulting PET plastic in PlantBottle packaging, the percentage varies for bottles that also contain recycled PET. For example, Denmark uses recycled content in its

• The company has analysed and uses the most environmentally friendly vehicle transport for its fleet and has trained employees in fuel-efficient driving (‘Eco Driving’).

www.foodbev.com/beverage January · February 2010

SUPPLEMENT 11

Sustainable packaging

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Sidel and Husky

Sustainable moves in producing and using recycled flake Plastic is often the target of virulent attacks because of its impact, whether real or imagined, on the environment. Bottle lightweighting drastically reduces the amount of plastic used, which in turn decreases waste. At Drinktec 2009 in Munich, Husky debuted its HyPET Recycled Flake system, which is specifically optimised for manufacturing preforms with high percentages of foodgrade recycled PET flake. In fact, the preforms produced on the Recycled Flake system at Drinktec were blown into the 1.5 litre mineral water bottles that Sidel was producing at the show. In addition, the Husky HyCAP system set up at Drinktec was producing a lightweight 1881 closure to fit the same Sidel bottle. The 1.5 litre mineral water bottle was produced on Sidel’s SBO 14 Universal2 at 2,000 bottles per hour per mold. It displays excellent technical performance identical to that of a traditional PET bottle. These performance levels are explained by the heating reserve available with the SBO Universal2 and by the oven configuration with 50mm pitch. The quality of heating also

Michael Hartman explains Eastman Embrace What are the main characteristics in terms of sustainability of Eastman Embrace shrink film?

Husky’s HyPET Recycled Flake system is able to run a blend of 50% virgin and 50% post-consumer PET flake ensures a wide processability window and impeccable bottle quality. However, there are limits, owing to regulations on the use of post consumer recycled materials for food contact applications: the percentage of recycled PET in bottles cannot exceed 25% as yet, and its use is also subject to national regulations. Sidel has the world record for blowing lightweight hot fill PET bottles and by combining great aesthetics with technical prowess has designed the new models Skyward and Curvy. These two 50cl bottles weigh only 18.9g and their design is a real breakthrough in hot fill, which traditionally produces bottles with six or eight panels that look exactly alike. Good material distribution is ensured by optimisation of the bi-orientation rates and preform thickness ratios, which are well suited to the bottle shape. Sidel is continuing its work and has already conducted laboratory tests on blowing bottles with 100% recycled materials, ready for market. This can be done without affecting blowing performance because of the wide process ability window for these machines.

Eastman Embrace copolyester and Embrace LV have outstanding physical properties, which makes this film stronger than competitive products and allows downgauging. Today our customers are able to reduce the material consumption by up to 20% per label. Does it actually use less product or is it just designed for lightweight bottles? Right, Embrace will allow use of less product and new machine technology to enable brands to reduce an additional 10% label weight for the same size shrink labels in the very near future. Also the stiffness of the material together with the 30% lower shrink forces, can be a plus when used in combination with thin wall, hence lightweight bottles. Are beverage manufacturers already trialing or using this? Yes, especially energy and mixed drinks in glass and PET are using Embrace LV copolyester films to enhance the look of their product with a 360° billboard effect on the primary package to attract and inform customers. What are the expected savings? Another unique property of Embrace LV is that the shrink fitting properties are consistent around the bottle. This means in comparison to

competitive films it does not shrink in machine direction it actually grows. As a result the brand wins one label for every ten produced. Are there any limitations on the type of bottle used? Embrace is the plastic copolyester resin with the highest shrink characteristics - up to 78% shrinkage is possible. Hence almost all unique shapes in the industry can be used. Is there a case study which can demonstrate it? Mirroring sports equipment, Gatorade requires packaging that is sleek and ergonomic, illuminating the brand in the best possible light. To ensure the greatest exposure Gatorade uses Embrace copolyesters for shrink film technology to maximise shelf appeal with a perfect wrap around showcasing the product, the colours and graphics of the brand. This perfectly contoured finish gives compelling reasons for using high quality resin and Embrace shrink film technology from Eastman Chemical Company.

12 SUPPLEMENT

www.foodbev.com/beverage January · February 2010

www.foodbev.com/beverage January 路 February 2010

SUPPLEMENT 13

Sustainable packaging

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KHS making strides in safe filling and environmental responsiblity

athias Gernhuber, Product Manager Bottles and Shapes, for KHS explains the company’s latest moves in lightweighting, water and energy reduction, waste management and bottle to bottle PET recycling. How does KHS view sustainable packaging? Today’s packaging philosophy has to adhere to two main criteria: First is safe filling and product protection and the second is social responsibility with regards to sustainability. We currently see the advantages of PET in terms of strength, brilliance and migration behaviour. To keep these advantages for today’s consumer the goal is to lightweight bottles and the subsequent step is to ultra-lightweight them. The weight reduction of PET bottles in the last ten years has increased by 55%. And we will see another 50% weight reduction by 2015. These sophisticated goals will be achieved by stabilising bottle shapes, stretch blow repeatability (using KHS Blomax technology) plus optimisation of bottle handling on the present filling lines. Today’s consumers have generally accepted lightweight bottles. Furthermore we now see lightweight packages as a necessity and not linked to a low price product segment. It is a few years now since biodegradable plastics entered the market. Benefits are on the one hand the ability to use such materials on standard line equipment and on the other hand the reduction of carbon footprint by 50 to 60%. Due to

the limitation of product shelf life (solution: KHS Plasmax coating technology) we currently do not see major potential in this plastic bottle segment. Nevertheless these materials are still in a development phase. A current trend with respect to sustainability is to design bottle shapes and blow molds (as well as stretchblow molders) with the aim of reducing energy and blown-air consumption, and moreover the use of produced heat energy. This comprises roughly 5% of the carbon footprint for bottles progressing from the raw material to the package in consumer hands. This energy consumption has been reduced over the last ten years by about 50%. As for the future we see further saving of about 25% up to 2015. We also see trends to convert production plants as well as plastic waste for ecological reasons: Water consumption, emissions, waste management, and bottle-to-bottle PET recycling are all keywords here. What in your view has been the greatest development in sustainable packaging within the last year or so? A milestone in PET bottling last year was the KHS 500ml bottle with a weight of only 6.3g. It was developed to show actual opportunities and was running on KHS standard equipment.

Has lightweighting gone as far as it can do? From the technical point of view we say: “Yes!” We see lightweighting as an ongoing trend which leads to an interaction of technology and the customer where both parts needs to co-operate. Furthermore most actual consumer bottles are blown on equipment which does not utilise the latest technology. The goal should be to adapt to the lowest package weight for each single piece of equipment. But the economic crisis of the last few years has interfered with technology investment. More and more projects have to begin using existing line equipment based on ‘Life Cycle Solutions’. And even though the technology to achieve the lowest possible weight levels is available, not all machines are set up to use this. What is the next step in sustainable bottle blowing? Our new KHS ‘Blomax series IV S’ machines demonstrates:

1. Preform heating using NIR technology saving up to 25% energy.

2. Servo driven stretch systems ensure a stretch speed adjustment independent of machine output. For example: A 500ml bottle will achieve best material stiffness at nominal output and high speed stretching. In comparison to this a 2 litre bottle runs at only 50% nominal output on the same equipment. This clarifies how halving the stretching speed lowers PET rigidity by up to 30%. Normally, this effect must be compensated for by increasing the amount of PET material, but on the new KHS Blomax series IV the highest possible stretch speed can be adjusted independently from the output. This ensures highest material robustness in combination with perfect lightweighting results.

3. We now have the largest process angle due to combined mold close and locking movement in one step (no further angle for mold locking necessary) this results in further reduction of blowing pressure as there is a longer contact time in the mold. What are the big issues now in sustainable packaging? The price of virgin PET is currently at a very low level so the return on investment for lightweighting projects and recycled PET manufacturing is also low. In combination with the bank credit situation some projects are on hold or - and this is a pity - will no longer be realised. How do you see the various packaging formats in terms of sustainability? Today the lightest 1.5 litre CSD bottle needs around 30% less PET material per 100ml filling than the lightest current 50cl bottle. This is a fact. But there is also an ongoing trend to smaller bottles. Firstly many healthy, fruit (smoothie) beverages come in small volumes with a filling level between 80ml and 250ml, and secondly the 330ml alucan never has been adapted to a PET bottle with respect to size.

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Tetra Pak and CSI

Tetra Pak driving growth in carton recycling

ichard Hands, Environment Manager, Tetra Pak UK speaks out on sustainability as a commercial imperative. the packaging industry. The primary function of food and drink packaging is to minimise food waste, making it safe and affordable everywhere - but, as green concerns rise on the consumer agenda, sustainability is a key consideration, both for the environment, and as a commercial imperative.”

What is your view of sustainable packaging?

Who do you see as driving this growth sector - consumers, retailers, packaging designers, or manufacturers?

“We believe that sustainability is crucial to the future of

“Consumers, retailers, packaging designers, government and

manufacturers all have a role to play in driving sustainability. The 50% reduction in the number of carrier bags issued this year compared to 2006 shows that consumer education is vital to inspire mass social change and the same is true when it comes to packaging. While the BRC’s recycling logos have set a good precedent, manufacturers and retailers need to do more to ensure a transparent and holistic message to consumers - one that looks at the entire product journey, including post-sale.“ What are the key developments for your company in sustainable packaging?

“Cartons have a great environmental story to tell - they are widely recyclable, lightweight and have a low carbon profile. Cartons can now be recycled in 86% of Local Authority areas in the UK, and one in five Local Authorities (20%) now even collect them at kerbside. What’s more, as part of our commitment to responsible forest management, 75% of Tetra Pak cartons in the UK and Ireland now use paperboard sourced from FSC certified forests and other controlled sources. This means that many UK and Irish customers can now use the Forest Stewardship Council (FSC) label across many of the nation’s favourite brands.”

CSI sustainability - more than ‘green’

s a packaging leader in the beverage industry, CSI is committed to helping bottling customers achieve their sustainability goals without giving up performance. CSI’s beverage closure portfolio includes a full range of high performing, lined and linerless short height mini closures as well as a variety of other new lightweight plastic closures for cold filled, hot filled, and aseptically filled beverages. In addition to the environmental and economic benefits associated with reduced weight packaging, CSI’s Xtra-Lok mini profile uses the ‘Sure Grip’ knurl, that makes it easy for consumers to grip. Two of the newest mini profiles being offered by CSI are Omni-Lok mini 28mm and Aqua-Lok mini 26mm. OmniLok mini 28mm is a one piece closure, precision engineered for carbonated and sparkling beverage applications. This versatile closure is engineered for packaging sizes ranging from 250ml up to 2.5 litres in size. Omni-Lok mini has enjoyed wide commercial success, having been adopted by major bottlers for use on flagship brands . The Aqua-Lok mini 26mm cap is compatible with 1901 and other

26mm short height 3-lead bottle finishes. This low profile closure and short height bottle finish provide resin material savings of up to 40% over existing 1844 26mm standard finishes. This lightweight closure establishes a new standard in material reduction and conservation while maintaining all the sealing performance, reliability, and ease of use bottlers need.

CSI also offers a family of lightweight, superior venting non-carbonated beverage closures for aseptic and hot fill packaging applications in both 38mm and 28mm sizes.

maintains the seal with hot fill vacuum packages, but allows excessive pressure due to fermentation to vent, which provides the product with improved consumer safety.

The latest aseptic closure design is the Asepti-Lok V38 3S closure. CSI has assumed a leadership role in global aseptic applications for juices, nectars and isotonic (sports) drinks.

For a more robust seal design in an extremely lightweight closure, CSI recommends its new ExtraLok 38mm OD lined cap.

For hot fill applications, CSI’s Extra-Lok 38mm OD lined

closure is one of the lightest weight 2-lead 38mm closures on the market. Its unique liner profile enables customers to reduce their bottle finish thickness without compromising performance. This cap’s design

In addition to the 20-40% material savings resulting from CSI’s lightweight closure systems, bottlers have realised

unprecedented line efficiency improvement when partnering with CSI capping experts for their short height and lightweight conversions. Today, beverage closures are lighter weight and higher performing than ever . . . a combination that benefits the environment, the consumer, the bottling customer and all stakeholders in the supply chain.

www.foodbev.com/beverage January · February 2010

SUPPLEMENT 15