Resource efficient packaging Andy Dawe Head of Retail Programmes WRAP

Presentation outline Introduction to WRAP Why is packaging optimisation important? Recycling Delivering optimised packaging Tools to help

Introduction to WRAP

WRAP – Waste & Resources Action Programme Private company, funded by Defra and the devolved administrations WRAP helps individuals, businesses and local authorities to reduce waste and recycle more, making better use of resources and helping to tackle climate change.

Our priority areas Packaging Collection Systems Quality of Materials Food Waste

THE RESOURCE EFFICIENCY LOOP

Why is this important?

Prime Minister’s Strategy Unit New Packaging Strategy, to be developed within the framework of the Waste Strategy for England (2007) Encourage prevention, reuse and recycling Improve information flow New Courtauld Commitment style voluntary agreements for packaging reductions by 2012 and new objective to encourage use of recycled materials

Courtauld Commitment The signatories commit to supporting WRAP in the achievement of its objectives: To design out packaging waste growth by 2008 To deliver absolute reductions in packaging waste by 2010 Reduce the amount of food wasted in UK homes by 155,000 t by March 2010

Removal of packaging at check-out Source: The Guardian, 15th November 2006

Landfill: zero food and packaging waste to landfill from 2015 Commercial and industrial wastes: to achieve a 20% absolute reduction in food and packaging waste arising at food and drink manufacturing premises by 2010 against a 2006 baseline Primary packaging: to make a significant contribution to WRAP’s work to achieve an absolute reduction in the level of packaging reaching households by 2010, compared to 2005 Labeling and information: to provide more advice to consumers on how best to recycle or otherwise recover used packaging

Waste prevention reviews Supporting the FDF's 5 fold Environmental Ambition Thinking differently through considering food and packaging from factory to fork with 'lean' thinking in resource efficiency Will develop and share good practice through case studies A number of benefits are being quantified - cost and carbon

Integrating primary, secondary & tertiary packaging Cereal carton size 50T CO 2 14T 44T CO 2 4T 6T CO 2 264m 2 X 10 Materials: carton board and corrugated storagedistribution For 1million cereal packets sold: By reducing the carton of a cereal pack by the dimensions of a small matchbox (8 x 35mm) the end result would be a reduction in material usage of 18T (50T CO2), saving of finished goods storage area equivalent to a tennis court (264m2) and the removal of 10 vehicles off the road for trunking of stock.

Recycling

Last year 8.7 million tonnes of waste was recycled in England alone. More than doubled in the past 5 years. Yet recent negative reports question its worth. IS RECYCLING WORTH IT?

We need three earths to sustain the way we live today. It is key that we address this issue now as there is still much more to be done. Markets are stabilising and demand is increasing. End markets are being explored. Recycling is working but we must continue the momentum. We must focus on the resource efficiency loop which will bring real benefits to the economy.

Delivering optimised packaging

Your options: Remove packaging completely De-layer the pack Reduce the number of components in a pack Down-gauge packaging material (make it thinner) Light-weighting and right-weighting a pack Right-sizing (reducing the head space in a pack or offering a range of portion sizes to customers) Refill packs / reusable packs (simplification?) Changing packaging formats and materials Structural re-design or re-engineering of the pack Concentrates, product compaction and reformulation

De-layering: Cadbury’s Treasure Eggs

Tesco 68% less packaging Starpack Gold Medal Winner De-layering and simplification: M&S: 69% less packaging and 6 days more shelf-life

Thinking Differently Thermoformed trays replaced with vacuum pack or flow wrapped bags ‘Organisation rails’ provide order and consistency to presentation Extra surface area used for product and brand communication

Your options: Remove packaging completely De-layer the pack Reduce the number of components in a pack Down-gauge packaging material (make it thinner) Light-weighting and right-weighting a pack Right-sizing (reducing the head space in a pack or offering a range of portion sizes to customers) Refill packs / reusable packs (simplification?) Changing packaging formats and materials Structural re-design or re-engineering of the pack Concentrates, product compaction and reformulation Pack innovation (breaking the category rules?)

Reducing packaging components Savings: Greencore Frozen Foods has reduced the pack weight of five different products by an average of nearly 70% during 2007, saving 115 tonnes of plastic Move away from packing in multiple plastic trays inside bags to new “form and fill” technology, whereby products are placed loose in film bags. More products can fit on each pallet – helping to reduce transport needs

Your options: Remove packaging completely De-layer the pack Reduce the number of components in a pack Down-gauge packaging material (make it thinner) Light-weighting and right-weighting a pack Right-sizing (reducing the head space in a pack or offering a range of portion sizes to customers) Refill packs / reusable packs (simplification?) Changing packaging formats and materials Structural re-design or re-engineering of the pack Concentrates, product compaction and reformulation Pack innovation (breaking the category rules?)

Can light-weighting

Savings: 5% weight saving (15,000 tonnes) New can body target thickness is only 0.097mm wide – about the width of a human hair Over 6.5 billion cans so far, saving 88,000 tonnes of CO2 Average 50% recycled content Manufacturer: Beverage Can Makers Europe Brand-owner: Coca Cola (Europe) Ltd Aluminium can light-weighting

Your options: Remove packaging completely De-layer the pack Reduce the number of components in a pack Down-gauge packaging material (make it thinner) Light-weighting and right-weighting a pack Right-sizing (reducing the head space in a pack or offering a range of portion sizes to customers) Refill packs / reusable packs (simplification?) Changing packaging formats and materials Structural re-design or re-engineering of the pack Concentrates, product compaction and reformulation Pack innovation (breaking the category rules?)

Structural re-design The old and new Coca Cola Contour bottles

Ultra lightweight formats 10g ‘no-bottle’ USA

Your options: Remove packaging completely De-layer the pack Reduce the number of components in a pack Down-gauge packaging material (make it thinner) Light-weighting and right-weighting a pack Right-sizing (reducing the head space in a pack or offering a range of portion sizes to customers) Refill packs / reusable packs (simplification?) Changing packaging formats and materials Structural re-design or re-engineering of the pack Concentrates, product compaction and reformulation Pack innovation (breaking the category rules?)

Optimisation tactics – Reducing headroom

Your options: Remove packaging completely De-layer the pack Reduce the number of components in a pack Down-gauge packaging material (make it thinner) Light-weighting and right-weighting a pack Right-sizing (reducing the head space in a pack or offering a range of portion sizes to customers) Refill packs / reusable packs Changing packaging formats and materials Structural re-design or re-engineering of the pack Concentrates, product compaction and reformulation Pack innovation (breaking the category rules?)

59g 23g Refills offer easy materials savings opportunities and the ability to innovate Innovation in refill packs and ease of use

The old and new Boots ‘Botanics Essentials’ gift sets Pack simplification and reusability

Reuse is even better Project Sofa Returnable packaging Logistics are key

Your options: Remove packaging completely De-layer the pack Reduce the number of components in a pack Down-gauge packaging material (make it thinner) Light-weighting and right-weighting a pack Right-sizing (reducing the head space in a pack or offering a range of portion sizes to customers) Refill packs / reusable packs (simplification?) Changing packaging formats and materials Structural re-design or re-engineering of the pack Concentrates, product compaction and reformulation Pack innovation (breaking the category rules?)

Changing pack format and materials Weight: 54g

15g 49g Format Change Same quantity of soup in a third of the material. Pouch is the premium product

Your options: Remove packaging completely De-layer the pack Reduce the number of components in a pack Down-gauge packaging material (make it thinner) Light-weighting and right-weighting a pack Right-sizing (reducing the head space in a pack or offering a range of portion sizes to customers) Refill packs / reusable packs (simplification?) Changing packaging formats and materials Structural re-design or re-engineering of the pack Concentrates, product compaction and reformulation Pack innovation (breaking the category rules?)

Asda Café Sandwiches: 56% packaging savings Better product visibility Flow wrap retains freshness for longer Better cube efficiency in distribution Before: 16g After: 7g Structural re-design

By using a folding box design rather than the former box and lid, the company has reduced the weight of the packaging from 68g for 200g of product to 26g for 160g of product, achieving a 48 per cent weight for weight saving.

Your options: Remove packaging completely De-layer the pack Reduce the number of components in a pack Down-gauge packaging material (make it thinner) Light-weighting and right-weighting a pack Right-sizing (reducing the head space in a pack or offering a range of portion sizes to customers) Refill packs / reusable packs (simplification?) Changing packaging formats and materials Structural re-design or re-engineering of the pack Concentrates, product compaction and reformulation Pack innovation (breaking the category rules?)

Complete product reformulation

2 x concentrated fruit squash Double concentrated squash means the 3L squash bottle has been replaced with a 1.5L bottle, generating a bottle weight saving of 35g (46%) and avoiding the need for a handle. This innovation generates a saving of 469 tonnes of plastic per year.

Some tools to help

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