Presentation on Total Recyclable Packaging Solutions for MAP Retail Products

PET and Other Polymers in Perspective Oil is the primary source for nearly all polymers used in packaging.  Even sustainable polymers such as PLA and cellulose have to be processed in chemical plants. This consumes fossil fuels in order to do so Only a fraction of the worlds oil ends up as polymer. The majority of oil is converted (cracked) and burnt as fuel.  Each day 1.51billion litres (1.1 million tes) of petrol is consumed in US automobiles. This will be a similar figure for Europe’s population.  If the residue from cracking fuels was not used, it would have to be land filled or disposed of by some other means.  Polymer production converts the waste stream products from fuel production into safe usable materials for mankind How are plastics made and were do they come from ?

Para-xylene Terephthalic acid + Gycol PET Only a fraction of the naptha ends up as PET film PET in perspective. Where does it come from ?

Carbon dioxide footprints can be generated for any application, no matter how strange. The import point is to put everything into context and be sensible how we approach the outcomes –Driving a car and using 1 gallon ** (4.45l) of fuel = 11850g CO 2 –Contribution of the green house gasses emitted from a cow used to produce a ¼ lb (114g) beef burger = 2600g CO 2 * –Leaving a 60 watt tungsten bulb on for 1 hour = 30g CO 2 –Taking the elevator + to up 4 floors (20m) = 13g CO 2 –Carbon footprint of a typical PET ready meal lid = 3g CO 2 Putting CO 2 Emissions into Context

Why choose PET ? PET is considered a ‘green’ polymer it comes from a clean process of manufacture with no waste stream. The source of PET is a “by product” of cracked oil which would otherwise have to be disposed or occupies land fill. PET is the most recycled resin in the world. I will talk about R-PET in my next slide. Unmatched thermal and mechanical properties per unit thickness of all packaging polymers. Therefore you can down gauge packaging without compromising pack integrity. Why choose PET ?

What is R-PET / PCR & PCW ? R-PET is PET that contains a recycled content which comes from Post consumer recyclate( PCR). PCR comes from Post consumer waste (PCW) which is PET material collected from households via local councils initiative or material deposited into recycling banks. This material is then sent to MRF ( Material recovery facility ) were is it separated and plastic is then sent to for re processing. Specialist processors are then able to clean the material and process it in a food safe format. For plastic which is in direct contact with food the R-PET has to come from certified R-PET suppliers with “superclean” processes in place. Also the R-PET has to be certified for direct food contact.

Food Compliance certificate for R-PET films

MAP Systems offers a total recyclable solution for ready meals, flow-packed & thermoformed products. High Clarity films in Barrier & Non Barrier Range of closure types from ‘easy peel’ to strong tamper evident permanent seal with ‘weld-cold’, peel-hot options. Plain & Printed films for high quality graphics Available with anti mist properties Dual ovenability & Cook-in-pack convenience Exceptional odour & aroma barrier RPET Base Web – PET with > 40% recycled material from traceable sources. MAP’s Offer

ProductPack Weight Reduction Production Impact (if any) Cost Timing (availability) Re-cyclability Cooked meats Fish (retail) Bacon Average 20% with also 30% re- cyclate in pack Possible knife replacement on thermo-formers. APET harder to cut Average 25% pack cost increaseAlready on shelf Totally recyclable within PET system Fresh chicken50% on Lidding film with up to 30% re-cyclate in film and 40% in tray NoneNeutralNowIf use RPET tray total pack recyclable Fresh meat50% on Lidding film with up to 30% re-cyclate in film and 40% in tray None Up to 40% increase in Lidding film. Tray neutralNowIf use RPET tray total pack recyclable Pasta (Fresh) Vertical form fill & seal Depending on current barrier films. Average 50% weight reduction. Also 30% re-cyclate in film None Depending on materials print or plain up to 100% increase Now Total pack recyclable Pasta (Fresh) Horizontal thermoform Average 20% with 30% re- cyclate in film Possible knife replacement on thermo-formers. APET harder to cut Average 25% pack cost increaseAlready on shelf Total pack recyclable Product Ranges in Recyclable Format

ProductPack Weight Reduction Production Impact (if any) Cost Timing (availability) Re-cyclability Cheese Vertical form fill and seal & flow wrap Up to 50% weight reduction depending on current materials with up to 30% re-cyclate None Depending on materials up to 50% increaseNow Total pack recyclable Cheese Horizontal thermoform Average 25% with up to 30% re-cyclate in pack Possible knife replacement on thermoformers. APET harder to cut Average 25% pack cost increaseNow Total pack recyclable Produce Weight neutral up to 30% recyclate in filmNone Depending on materials up to 100% increaseNow Total pack recyclable Ready Meals Weight neutral up to 30% re-cyclate in film and trayNoneNeutralNow Total pack recyclable Print OptionAll films can be sandwich or surface printed and can still be used in the recycling process Product Ranges in Recyclable Format

OptionsStandard Format Recyclable Format Film Specifications ( Top)12/45 PET-EVOH-PE AF 13/23 PET Barrier peel AF Film Specifications ( Base)270/50 APET/PE peel clear 270 R-PET clear Width /Pack size ( Top & Base)561 & 562 mm/ 190* 127 mm Plastic weight used ( Approx)32 tonnes tonnes= 192 tonnes 160 tonnes ( 17 % reduction) Plastic into landfill 192 tonnes 0 tonnes Existing Thermoforming format vs. Recyclable Mono solution

In Summary Current packaging that goes into Landfill is 192 tons for this application. Moving to MAP PET will mean a reduction in 17% ( 33 tons reduction) of plastics used in this pack format without compromising pack functionality. Being an APET film were facilities permit the film is recyclable just like PET bottles. Also up to 40% Re-cyclate can be used in the film which a percentage comes post consumer waste sandwiched between the layers of film. All coating barrier/ sealing layers & anti-fog can be removed in the recycling process.

Reasons Why Recyclable Packaging Solutions will become Cost Neutral or more Cost Effective within Plastic Packaging. As more Tonnage of PET is recycled (including Food Packaging), there should be a drop in Price of RPET The use of RPET will be widely introduced into the virgin system of manufacture leading to more Efficient, Cost Effective Manufacturing Methods (particularly on Top-web). Polyester is not effected as dramatically by Oil Prices as other Polymers Landfill Charges will be at far Higher Rates in the next few Years Households will be charged for the disposal of Non-Recyclable Packaging, therefore a Higher Pack Price could still be cheaper to the consumer. If Carbon Taxes are introduced, the Packaging Offset will be significant particularly with the use of PCW (Post Consumer Waste) within the Packaging i.e. 30% Weight Reduction, 40% Re-cyclate and 100% Recyclable

Netherlands to launch Carbon-Based Packaging Tax. New Legislation comes into effect on 1 st January Tax based upon calculation of CO 2 emissions from the Production of each Kilogramme of Packaging Material, plus the embedded Carbon Content of the Packaging. Tax revenues will be used to establish separate collection of household Packaging Waste. Target is 42% recycling by EU commission expects this to be the Start of a Europe Wide drive, by forcing companies to add CO 2 emission's to their list of criteria when choosing their Packaging.

New Bin Bag Tax : Households to be Charged for filling more than ONE sack. Families who throw out more than one sack of rubbish each week are being forced to pay a controversial "bin bag tax". In a scheme which could soon be rolled out across the UK, dustmen will be ordered not to collect refuse unless it is left in official colour-coded bin bags provided by the council. Homes will be given just one free sack every week and must pay 28p for each additional bag - at least three times as much as an ordinary black bag from a supermarket. That would leave a typical family producing four bags of rubbish a week paying £40 a year to their local authority on top of council tax.

UK to toughen Packaging Waste Targets Tougher packaging waste targets in the UK are due to come into effect in January The new business targets would come into effect in January 2008 to help the UK meet its obligations under the EU's packaging directive. The UK, like other EU members, is attempting to meet the obligations, forcing manufacturers to switch to more eco-friendly packaging. The proposals would require more packaging to be recovered and recycled, environment minister Joan Ruddock said. The UK government wants to increase the recycling target to 55.7 per cent in 2008, 56.8 per cent in 2009 and 58.4 per cent in The recovery target would be 60.6 per cent, 61.8 per cent and 63.4 per cent in the same years.