Consumer demand for eco-friendly products and packaging is increasing, often referred to as the ‘war on plastic.’ However, this overlooks the numerous advantages of plastic packaging and neglects the fact that, with the right material selection, design, and end-of-life approach, plastic can be one of the most environmentally friendly materials in packaging.
We acknowledge the associated risks in altering how a product is packaged, and for many manufacturers, plastic remains the only practical and environmentally viable packaging solution. Following our previous discussion on the sustainability aspects of metal cans, in this article, we engage in a conversation with Brian Lodge, Design Manager at Berry Global, about sustainable design practices, with a focus on the effective use of plastics.
If you are contemplating a redesign of your product packaging with sustainability in mind, we hope you find this information valuable. As a leading industry expert in coding and marking, we are here to assist you in mitigating some of the risks associated with sustainable design.
The Battle Against Plastic
In the 1940s, when plastic packaging initially entered supermarket aisles, it was celebrated for its numerous advantages – being lightweight, cost-effective, and possessing excellent barrier properties. Plastic facilitated the processing, packing, and transportation of food, expanding the range of available produce for the public. The merits of plastic packaging seemed limitless. However, in the contemporary era, consumer attitudes towards plastics and their usage have become less favorable.
Presently, challenges related to the recycling and disposal of plastic packaging have resulted in ubiquitous images of waste and increased awareness of plastic’s environmental impact. Consequently, many brands are under growing media scrutiny to distance themselves from plastic packaging and explore alternatives perceived by consumers as more eco-friendly.
But is completely avoiding plastic packaging truly the solution?
The Challenge of Transition
If your current packaging material is plastic, making a shift to an alternative can be problematic – both in terms of environmental impact and practicality.
“At Berry, we engage with many individuals who have thoroughly researched alternative packaging materials and are facing immense pressure to abandon plastics, even when there is no suitable alternative for their product,” says Brian Lodge, Design Manager at Berry Global. “Blaming a material is an easy solution, but plastic is not the sole issue, and an outright ban on plastics would simply relocate the problem.”
Earlier this year, a cross-parliamentary group in the UK cautioned that consumer insistence on eliminating plastic packaging in stores could, in fact, be detrimental to the environment. Many materials considered more sustainable may have a more damaging environmental footprint. For instance, while glass is fully and widely recyclable, its greater weight compared to plastic makes transportation more polluting.
From a practical standpoint, altering the packaging of a product can also present significant challenges for manufacturers. Even minor changes can have cascading effects on production processes. An often overlooked consideration is ensuring that the new material can be consistently and clearly coded with machine- or human-readable codes that endure the required lifespan of a product without compromising its recyclability.
Advocating for a circular economy in plastic packaging recycling
Effectively addressing this challenge necessitates a meticulous examination of plastic design, utilization, disposal, and collection. Globally, recycling rates for plastic packaging are remarkably low—approximately 20% of all plastic waste was estimated to be recycled in 2015 [8]. As the demand for plastics continues to rise, end-of-life plastics should be viewed as a resource rather than mere waste. Measures must be implemented to capture, recover, and reuse all plastics at the end of their life, preventing their accumulation in landfills or the natural environment.
In 2018, the Ellen Macarthur Foundation, in collaboration with the UN Environment Programme, introduced The New Plastics Economy Global Commitment. This initiative urges brands and organizations to collaborate in creating a ‘circular economy’ for plastics. Over 400 organizations, including Nestlé, PepsiCo, Unilever, Veolia, and Walmart, have joined this commitment to fundamentally rethink and redesign the future of plastics.
Simultaneously, the petrochemical industry globally is actively supporting the transition to a circular economy. This involves efforts to enhance the quality of post-consumer recycled (PCR) plastics and research into chemical recycling. Unlike mechanical recycling, which melts down and reforms plastic, chemical recycling aims to revert plastic polymers to their original feedstock. For many, chemical recycling is pivotal in closing the gap in the plastic chain.
“Chemical recycling has a role to play in the reuse of valuable materials and keeping more plastics in the value chain, but the technology is still in its infancy,” notes Lodge. “So, mechanical recycling still has a significant role to play, but whatever the technology, we need to work towards getting a good, pure stream of plastics going into the system so that we can get a good stream coming out.”
How can I enhance the sustainability of my product packaging?
Transitioning to a circular economy for plastics requires intensified efforts and collaboration between governments and key stakeholders throughout the plastics industry to standardize materials and recycling systems. This encompasses not only plastics producers and recyclers but also brand owners, manufacturers, and retailers.
If you are engaged in product packaging design, there are several crucial actions you can take to bolster your company’s sustainability credentials and contribute to addressing the plastic waste challenge:
Codico is available to offer assistance
For some, transitioning away from plastics is not always feasible or desirable. The encouraging news is that plastic packaging can still align with sustainability goals. If your current packaging material is plastic, it’s crucial to explore available options for your company and identify the most suitable solution based on your specific needs.
As a prominent player in the coding and marking industry, we are actively working to mitigate some of the challenges associated with designing for sustainability. We are developing laser and ink coding solutions tailored to a variety of new packaging materials, including recycled, recyclable, and bio-based plastic packaging.
At the Domino Laser Academy in Germany, our technical specialists are dedicated to creating solutions for new single-layer and lightweight plastics by conducting in-depth analyses of substrates at the molecular level. An exemplary instance of this is the development of a 9.3μm wavelength ‘blue’ laser tube designed for secure coding of lightweight, recyclable, and plant-based PET materials that do not biodegrade.
Similarly, Domino’s in-house Ink Development and Global Pre-Sales teams have collaborated to formulate a range of ink solutions suitable for single-layer, recyclable plastic films crafted from polyethylene and polypropylene. This includes BOPP film intended for use in food packaging.
Anticipated advancements in new and enhanced plastic packaging are expected to unfold over the coming years. Therefore, Domino is committed to staying abreast of these trends and responding with innovative technologies to deliver optimal coding solutions capable of addressing the latest substrates.
No matter where you are on your sustainability journey, Domino is here to provide support. Our experts are available to offer guidance on producing products that meet the approval of retailers, are valued by consumers, and are trusted by those with environmental concerns.