Packaging: The best way to reach (or come close to) zero waste

The best way to reach (or come close to) zero waste

The concept of zero waste packaging has become all the rage recently. But, is it really possible to achieve such a goal, especially in the baking business? To answer this question, we need to first define a sustainable package.

+Typical definitions of what sustainable packaging entails revolve around recyclability, the use of recycled or bio-materials, or compostability. The problem with these is that they ignore the key functions of a baked goods package, which include protecting the freshness of the product inside, maximizing shelf appeal in the store, and maintaining taste appeal at home.

When you consider that the food inside the package produces up to 20 times the environmental impact of the package itself, the role of packaging is far more important than people realize. To put it simply: Food waste is a significantly bigger concern than packaging waste.

Given this reality, my definition is a bit more holistic:

Sustainable packaging delivers the full value of the product(s) contained within and does so with the least amount of negative economic, environmental, and social impact throughout its lifecycle. Given this definition, and the fact that wasted food is a far bigger environmental issue than its packaging, the concept of zero waste should really be focused on the product rather than the package. In fact, studies are showing that sometimes the best way to reduce food waste is actually to increase the amount of packaging used, and thus the amount of packaging discarded.

So, after you have designed packaging that minimizes product waste by maximizing product protection and appetite appeal, what options can be pursued when working to minimize packaging waste?

Recyclable materials

Oftentimes, the term ‘recyclable’ is just a theory. Virtually anything can be recycled for the right investment. The key is to focus on materials with a proven record of being collected and reprocessed. Paperboard, PET and HDPE come to mind. Some flexible or ‘soft’ plastic packages may be an option,

especially those using newer mono-layer technologies, but this is highly dependent on local regulations and available facilities.

The reason for the preference for recycled materials is that it generally takes less energy, and thus generates fewer greenhouse gases, than using virgin materials. This is a key point: reducing energy consumption is actually a more important sustainability goal than the choice of materials.

Packaging made from recycled materials

Even better than simply using recyclable materials is the use of post-consumer recycled (PCR) paper and plastic materials. By definition, they are both recyclable and recycled, generally with the most preferred environmental profile. It should be noted that it is important to specify PCR, as industrially processed materials, such as regrind, are generally deemed to be part of the typical production process and are not considered to be recycled.

Industrially compostable packaging

This type of packaging makes sense if your products are sold into restaurants and institutions where industrial composting facilities are part of the waste management equation. This is because it can be hard to separate packaging from wasted or spoiled food, or if food residue would contaminate packaging that could be recycled.

Keep in mind that for retail applications, where your products end up in consumers’ homes, compostable plastic packaging is not a recommended option. There are two reasons for this: Firstly, even if the packaging biodegrades to EN or ASTM standards, it does not produce anything of value. There is no compost or humus, nor are there soil conditioners. Further, the lack of complete biodegradation can lead to microplastic residues. Secondly, the biodegradation of these materials produces powerful greenhouse gases that include carbon dioxide and methane or ammonia. Thus, even if a material completely biodegrades in the composting process, the final result is environmentally negative.

Non-recyclable packaging

If the goal is to minimize waste production, there are times when packaging that is not being widely recycled can be a good option. Let’s consider 0.5Kg of dinner rolls, in one case packaged in a paperboard box, and, in the other case, packaged in a heat-sealed LLDPE bag. The box is made from 35% post-consumer recycled content and is easily recycled. The bag is made from virgin plastic and is not readily recycled. Even when you factor in the relatively high recycling rate for the box, it still generates four times the amount of waste than the non-recyclable plastic bag! This is because the weight of the bag is significantly less than the weight of the box. It is also because polyethylene is very efficient to produce and requires relatively small amounts of energy to do so.

High barrier packaging

A good example of where more packaging, or non-recyclable packaging, may be required is preservative-free baked goods. Modified Atmosphere Packaging (MAP) is probably needed to provide a barrier that will deter the growth of yeast and mold in these products. And, according to well-known food packaging expert Dr. Claire Sand, while freezing products in paperboard or film may be an alternative to MAP packaging, it does not work well for some baked goods due to starch retrogradation.

Conclusion

It should be noted that zero waste is an aspirational concept, and that waste minimization is the real objective. From both an environmental and economic standpoint, the best way to achieve this goal is to start by ensuring that your products are safely transported, displayed, purchased, and consumed. Whether you then decide to use packaging that can be recycled, is made from recycled content, or uses significantly less material than other types of packaging, is up to you and the preferences of your customers. +++

© kyrychukvitaliy – stock.adobe.com

About the author

Robert Lilienfeld is the Executive Director of SPRING, The Sustainable Packaging Research, Information, and Networking Group. He has been a sustainability consultant to the packaging industry since 1994 and is a regular contributor to baking+biscuit international.