PACKAGING DESIGN FOR ENVIRNOMENT AIN SHAMS UNIVERSITY INTERNATIONAL CONFERENCE ON ENVIRONMENTAL MANAGEMENT May 3-5 2008 PACKAGING DESIGN FOR ENVIRNOMENT BY : Dr /Noha Abdallah Faculty of Applied Arts ,Helwan university

ABSTRACT Environmental Impacts of packaging are considered an issue of importance and concern growing worldwide. Today our natural environment is negatively affected by accumulation of packaging waste. With packaging waste management planes and strategies that have been taken seriously by many countries all over the world, a strong Eco-design trend appears in all fields. From the scope of why not deal with waste management issue from the beginning this point to design package for environment; material selection start point and during its life cycle to the end of dealing with it as waste. This paper studies eco-design concepts and definitions, the effect of packaging waste on environment; air, water, litter.. , Eco design packaging tools. Analytical study including examples of foreign succeeded packages eco – redesigned has been made. In Egypt this global trend should be considered. The research also introduce environmental guidelines for Egyptian packaging associations that they should follow to evaluate their packaging according to environmental considerations so they can eco-design or re-design their packages to minimize waste and for healthy clean environment .

1- INTRODUCTION OF ECO-PACKGING Eco- design definitions Eco-design can be defined as” the incorporation of environmental considerations into any design”. What is Eco Packaging? “Packaging that still fulfils its functions but has less environmental impact over its lifecycle”.

The effect of packaging on Environment The negative effects of packaging can be summarized in the following table: Table (1) Negative effect Reason Packaging waste volume increasing Different type of materials and packages used Inconvenient structural packages design Smaller unit packages accumulation. Increasing packaging waste going to landfill Packaging Material selection - (e.g. non-recycled plastics, steel..). Consumption increasing of renewable resources (water, Trees, etc). Unsustainable use of these resources in all stages of packages life cycles Emissions to water , air and land (like hazardous Substances, suspended solids, ozone, acid gases....) Manufacturing, distribution, etc or waste management processes. Use of non-renewable and polluting energy resources (oil, gas, coal). Unsustainable use of Energy.

2 – STUDYING ECO-DESIGN AND ITS RELATIONSHIP WITH OTHER FACTORS Conventional Package design and Eco-design Customer requirements Environment Technical feasibility Cost control As it’s explained before the term “eco-design” means products (goods and services) designed with the environmental factor in mind. It implies that this factor is included with the rest of the conventional design ones (customer requirements, cost control, technical feasibility, etc.) .

Could eco-design be benefit to business ?

The specific business benefits of eco-design for packaging: Greater resource efficiency (materials, energy,.. Better product differentiation in over crowded markets. Reduced environmental impact during use and disposal . Opportunity for innovation (new product forms) . Added functionality and effectiveness .

Environmental Considerations & objectives It’s very important to specify the envirnomental consideration that we should be awared of and the objectives that we should seek. Envirnomental Consideration 1- Environmental health-toxic effects of all packages components . 2-VOC content-mass of volatile organic compounds . 3- Material utilization-product and packaging/delivery system across the life cycle. 4- Energy utilization-energy inputs to packaging/delivery system across the life cycle. 5- Virgin materials content-mass of nonrecycled materials in packaging/delivery system . 6- Nonrecyclable content-mass of materials in packaging/delivery system not readily recycled.

Environmental objectives: Environmental concern shall take into account several requirements as: Raw materiel selection at the design stage and minimum material usage. Energy consumption during operation; Minimum energy should be used during its life cycle, production/use /dispose of the packaging). Recycling capability at the end of lifetime ,It can be re-used (for other purpose). - Its materials can be segregate and recycle for future re-process. - Its materials are well recovered.

3- ECO-PACKAGING DESIGN GUIDELINES & POLICIES Envirnomental policies Many companies that take the eco-packaging trend seriously followed envirnomental policies that depends on : Technical information system developing to provide essential information and tools to help optimizeing green packaging. These include eco-design guides and checklists, calculation tools, pack design and labeling matrices. Selecting packaging materials and processes that minimize waste according to information system that have been studied, compliance with international regulations should also be taken into account. Studying the structural and functional elements of packaging design more deeply .

Eco-design tools can be very helpful. Many multinational companies use sophisticated tools or metrics, such as life cycle assessment (LCA). This is a well-known method for evaluating the potential environmental impact of a product system, from raw materials through production, use, recycling, and disposal .

Life Cycle Assessment (LCA) (LCA) is an analytical tool that serves to evaluate eco-design concepts. It examines inputs (like materials, resources, energy) and outputs (like emissions to air and water, waste) at every stage in a product’s lifecycle to then quantify its environmental impacts. A- Choice of materials B- Production C- Distribution D- Utilization E-End of lifetime

A- Choice of materials Optimization of the packaging function. Reduction of materials volume used. Choice of non-toxic or only slightly toxic materials in extraction, production, utilization and disposal (end of lifetime). Choice of materials based on renewable resources to save natural non-renewable resources. Choice of power-saving materials in raw material extraction, material processing and use. Use of recycled materials. Use of recyclable materials with a view to product recovery at the end of its lifetime. Choice of greener packaging minimum heavy metal content (lead, cadmium, etc.).

B- Production C- Distribution Selecting production method less impact to environment should be considered. Power consumption reduction at all stages of production (machining, cutting, casting. C- Distribution Reduction in the mass and volume of packaging. Optimization/reduction in transport: fewer masses and volumes to transport. Choice of means of transport using less fuel.

D- Utilization E- End of lifetime Packages utilization is a stage in packages life cycle, Eco–design should also include this stage into account by studying leakage, noise prevention,.. . E- End of lifetime As we have already said, recovery at the end of a product’s lifetime should be considered and should be taken in charge by its producer, the product must be designed so as to facilitate this operation.

Introducing new materials New materials are appearing that make of natural renewable re-sources and of course environment friendly. Mainly of plant origin, their composition means they are biodegradable and they can be safely managed as a waste. For example, plastics made from potato, corn, and wheat or starch - as an alternative to traditional oil -products - help avoid the depletion of non-renewable resources.

Can we benefit from other countries experience In eco-design field?

4- PACKAGING ECO-REDESIGN ANALYSIS STUDY Many association in some countries succeeded in re-designing their packages according to environmental consideration, table (2) indicate the various directions that have been used to packaging eco- design . From To Result 1- Rigid plastic tube Plastic Sachet Annual change - saving 5.75 T Paper - Saving 15.50 T plastic - Retail and Transit packaging material used Saving - Energy used Saving -Packaging and shipping cost saving.

PACKAGING ECO-REDESIGN ANALYSIS STUDY From To Result 2- High wide trigger bottle Smaller one Annual change- Saving 5.75 T Plastic – Saving 4.5 T paper.- Retail Packaging and transit Material used Saving- Shipping cost saving 3- 100 % Raw material 1/3 of the bottle made from post consumer recycled material HDPE. Annual change -10 T raw plastic Saving - Annual cost saving.

PACKAGING ECO-REDESIGN ANALYSIS STUDY From To Result one used journey corrugated box Returnable plastic crates. Annual change - Saving 50 T cardboard - 2 T Plastic stretch wrap - Energy Used Saving - Material Used Saving - Damaged during transport and handling reduction Card box with a laminate plastic window A plain card box with product picture on the art work. - 50 T paper Saving -3 T plastic Saving - Saving annual cost.

4- ECO PACKAGING IN EGYPT Eco packaging problem in Egypt Actually This global trend of eco design has not appeared yet in Egypt and unfortunately not taken into account from those whom working in packaging field, We have to take this issue seriously as it is considered a solution some how of packaging waste accumulation by dealing with it and any product from the beginning thus reducing the amount of its waste. Why not benefit from others experience in that field according to our situation in Egyptian markets.

Common Eco-design Packages Problems in the Egyptian market Actually there are many common packaging problems in the Egyptian market according to environmental evaluation which can be described as just examples in the following table: Common package problem The detrimental effect on environment Large package for small product. Volume packaging waste increasing

Common package problem The detrimental effect on environment Multi layer Package for food products. Land fill packaging waste increasing resulted from hard recyclable packages due to several materials used hard to be separated. Single use or small unit packages for small quantity of products. Maximum material usage resulted in packaging waste accumulation. One trip package for almost all products (non returnable containers) High consumption of materials and energy That increases the waste at the end of packages life cycle.

Case Study of a package design in Egyptian Market Package & Product relationship analysis Package Dimension (one face without sealing area) Height = 6.5 cm Width = 10 cm Product size Circular shape with 5 cm diameter 1cm thickness Conclusion 4 cm free space in width 4cm width x 6.5 height (in one face) total area 52 cm2 About 40 % of package area not used Re-sizing the package can save about 40 % of material used for each package and waste at the end.

Guidelines for Egyptian association to work with eco-packaging concepts Working with eco-packaging system goes into two directions: Introducing new eco-package system. Re-designing the existing packages according to eco-packaging system.

Ecological re-design Starting point and design process Starting point and design process of Eco-packaging introduction into packaging associations should go through the following steps: 1- Start from the package design and its production, distribution, consumption process, up to the disposal of the waste it creates. 2 - Consider the present situation and stress, its critical aspects in environmental terms. 3 - Figure out new solutions leading to reconsider the package itself and its production, distribution, and consumption system. 4 - Emphasize the environmental benefits it could allow. These questions listed in the table below could be helpful to packaging associations in evaluating their packaging system.

The Eco-packaging developing questionnaire form Assessment fields Questions Packaging selection Stage -Material -Structural design What kind of packaging is needed? Does the whole system (primary, secondary and transport packaging) use the minimum adequate amount of material to maintain the necessary level of safety, hygiene and acceptance for the packaged product and for the consumer? Is the material selected for package is environment friendly? Has the optimum relationship between primary, Secondary and transport packaging been achieved? Is the relationship between the volume of the contents and the volume of the packaging optimum?

Packaging selection Stage Assessment fields Questions Packaging selection Stage -Material -Structural design Can a change in design allow a reduction in the size or weight of the packaging while maintaining its capacity? Are pallets being used to the maximum? Are the dimensions of the primary and secondary packaging adapted to the pallet dimensions? Are additional materials such as intermediate layers, shrink wrap, adhesives, and tapes all necessary?

Assessment fields Questions Production Stage If present, is the combined concentration level of lead, cadmium, mercury and chromium in packaging or packaging components, less than 100 ppm? Does the packaging contain any other hazardous substances, as defined by appropriate legislation that might be expected to cause problems when the used packaging is re-used, recovered as energy or material or disposed of or landfill? Has the use of recycled materials been considered? Have steps been taken to reduce packaging production waste to a minimum? Can the environmental efficiency of the production process be improved? Can the losses during filling or packaging process be reduced? Is packaging waste that is produced during filling, recovered as a material or as energy?

Assessment fields Questions Distribution Can the average weight of deliveries be improved? If the packaging is returnable, can it be made collapsible or minimized in some other way to reduce transport volume during the return journey? Is the transporting system used less impact on environment? Utilization and disposal Can the original packaging be re-used at home for the same purpose if the contents are also made available in a less type of packaging? After use, will the packaging be capable of being recovered either as a material or as energy or as compost? Has the packaging been designed to facilitate separation of materials? In order to encourage recycling; have material identification symbols been considered?

Recommendation For packages eco-designed effectively, envirnomental consideration must be factored into projects from the beginning. Minimizing materials, resources and energy used for packaging should go through re-design of packaging taking into account; wall thickness, weight of packs reduction, increasing in density of the products transported and stored. Introducing new packages or modifying existed ones should be done using life cycle assessment and other eco-design tools, matrices and questionnaire. Manufacturing of new packages including recycled materials percentage should be considered (paper, cardboard, plastics, glass, and metals). It is recommended to design the package with a view of making them recyclable .

Recommendation Packages structural design in relationship with product volume as well as product requirement should be studied well in Egyptian packages. Environmental awareness should be increased from both consumers and manufacturer or producer. Using of multi layer package which is hardly recyclable had to be avoided or even decreased. Introducing new Eco-packaging system for new product or redesigning existing package could goes towards: An alternative to “single-use containers”. Concentrated products to be “diluted” at the moment of use. Products to be “spilled” at the point of sale in the desired quantity. A new generation of “returnable containers

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