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"Green" plastics - work in progress |
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September 2008 |
Developing viable alternatives for conventional oil-based polymers for use in the flexible plastics packaging industry is a ''work in progress''. Neil Engelbrecht of Knilam Packaging Solutions explains some innovative steps that have been taken so far on the road to creating environmentally-friendly films as well as the challenges that lay ahead.
/~Creating environmentally-friendly packaging is much like addressing the carbon emissions of motor cars running on petrol refined from oil. We are aware that cars contribute to carbon emissions, causing the increase in greenhouse gases, but it takes time and resources to bring about change. There are some environmentally-friendlier cars available, but the mainstream "conventional" petroleum-powered car market still dominates.
Likewise, there are environmentally-friendly films currently being produced by some flexible film producers. These are sometimes touted as the panacea to the need for sustainable "green" plastic packaging alternatives, but they do not dominate the industry yet. This is because they are neither practical nor affordable, and much work still has to be done to overcome the implementation problems that they cause.
Drivers for change
Leading international and local retailers are setting the pace for a switch to sustainable packaging alternatives. One leading British retailer's mantra concerning packaging and the environment is:
- Reduce - down-gauge packaging, remove lids, etc.
- Recycle - water bottles and paper.
- Renewable - trees, tapioca, corn, bamboo, etc.
Some targets on reduction, recovery and recycling have been set. But sustainability in a commercial environment cannot be pursued in isolation; it needs to be done with profitability and affordability in mind.
Response from the plastic packaging industry
The packaging industry has responded to the growing move towards environmentally-friendly packaging by producing some noteworthy products. These have been touted as the answer to oil-derivative plastic polymers and hence packaging film. They include:
- PLA, a biopolymer resin made from plants. It is being used to manufacture flexible film and rigid packaging products.
- Cellulose-based films similar to cellophane are now being used as alternatives for polypropylene film for food in a pillow pack application or pre-made bags.
- Sugar cane and moulded wood pulp food trays are being used to replace plastic trays (APET, PP, etc).
- D2W - an additive for PE and PP packaging films, which renders the product biodegradable.
These products have however, presented several hurdles and challenges in the production environment
Viable options
One current alternative that helps the environment and does not seem to have any performance limitations is RPET. This is a polyester film manufactured to contain up to 35% of post-consumer waste recycled PET resin.
Organic produce in some supermarkets is already packed in "green" trays with environmentally-friendly flexible film over-wrap.
Engelbrecht: Tel 011-472-4734; website: www.knilam.co.za
| The downside to the alternatives |
| Performance |
Performance of the products in the production environment, including yield of substrate and sealing conditions (dwell time, temperature and pressure), need to be evaluated in order to understand implications on the productivity of a production unit. |
Single source
suppliers
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Some packers and retailers are uncomfortable with a monopolistic situation in terms of biopolymer feedstock as well as capacity issues in the event of large-scale switches to these alternatives.
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Affordability
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Most viable alternatives come at a higher price, which impacts on affordability and profitability down the supply chain.
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Recycling
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The plastics recycling industry is concerned about biodegradable plastics negatively affecting recycled polymers when they mix with them in the stream - causing failure in some products made from these ''mixed'' polymers.
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Compostability
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If a plastic product claims to be compostable, manufacturers need to specify whether this refers to industrial compostability or home compostability.
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