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Jim Scott, JES Packaging PackExpo ‘09 Las Vegas October 6 th, 2009
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Man vs. Clamshell: A Lopsided Fight by David Segal, NYT, 9/27/09 “… companies want packages that are easy to transport, display products in a highly visible way and are hard to steal … The point is to create a package that cannot be opened and closed surreptitiously. That way, no one can remove anything and put the package back on the racks without it being obvious.”
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History of Trend toward PCR Plastic Packaging Sheet Extruders’ Imperatives Thermoformers’ Imperatives End Users’ Imperatives Retailers’ Imperatives Recyclers’ Imperatives Why Trend toward 100% Post-Consumer Content Recycled Plastic Packaging will Continue
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’80s – ’90s – Paperboard Pkg. “100% Recycled Content - Min. 35% Post-Consumer Content” Non-Food Contact due to FDA Concerns Late ‘90s – ’08 – Increasing interest in “Bio-Plastics,” eg., PLA – sometimes touted as “biodegradable”
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‘05 – Wal-Mart initiates its “Packaging Scorecard” ‘06 – ’09 – Increasing Questions on Performance, Cost, and Sustainability of Bio-Plastics and degree of biodegradability / compostability ‘08 – “Wal-Mart will become more aggressive in the near future: Material Reduction & Recycled Content” ‘08 – ’09 – Increasing demands by Major Retailers with “Truth in Environmental Labeling” mandates ‘09 – Wal-Mart initiates its Sustainable Product Index Greener Package initiates its “Anti-Greenwash” Guidelines
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Pentel introduces Recycled “Handy-line S” Highlighters
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More Sustainable versus Virgin or Bio-Plastics Equal or better Physical Characteristics and Performance Availability and Competitive Cost of FDA Food Contact Pellets and Flake … esp. PCR PET Claims can be readily Substantiated … and meet “Truth in Labeling” Mandates Supported by CPG Companies and Major Retailers
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Sheet Extruders’ Imperatives Sheet Extruders’ Imperatives Want Proprietary Manufacturing Processes and Equipment Capability to run Flake … not Pellets … may be necessary for High Quality and Consistency of RPET Need Multiple sources of Pellet / Flake, esp. FDA food grade RPET May need to move in stages from 35% to 100% Post- Consumer Content Due to new or less efficient processes … or increased demand … may need to significantly increase Production Capacity
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Thermoformers’ Imperatives Thermoformers’ Imperatives Want Proprietary Manufacturing Processes and / or Package Styles Need to offer Cost Competitive, Sustainable Packages May need to move in stages from 35% to 100% Post- Consumer Content
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Thermoformers
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End Users’ Imperatives End Users’ Imperatives Want Unique Products and /or Packaging vs. Competition No Increase in Cost, but … No Sacrifice in Production Efficiency or Performance Driven mostly by Major Retailer Demands … esp. WalMart * Cost has been #1, #2, and #3 * Environmental Issues beginning to be seriously considered On-Package Environmental Claims must be believable to Consumers … and be readily Substantiated
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End Users
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Earthbound Farm America’s largest grower of Organic Produce July, ’09 - announced that all their clamshell fresh cut salad pkgs. are being made from 100% post- consumer Recycled PET RPET is being supplied by Packaging Plus
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Earthbound Farm Based on 2008 Annual Usage, use of 100% RPET: Will conserve 424,000 million BTUs Will conserve 68,307 gallons of water Will eliminate 16,191 tons of CO2 Will divert 1.3 million lbs. of Solid Waste from landfills
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Sustainable Packaging Coalition (SPC) Sustainable Packaging Coalition (SPC) “ Earthbound Farm’s PCR PET initiative is a perfect example of how to get the ball rolling in the right direction.” “We hope to see more companies that make that commitment, creating a market for these materials …” Anne Johnson, Director SPC
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Subway Subway Changing Plastic Salad Bowls: Redesigned to reduce use of plastic Switched from OPS to 10% PCR PET Will reduce plastic material use by 712,00 lbs. annually Will eliminate 19,500 corrugate cases annually Will reduce carbon footprint by 21% or 84.8 kgm of Carbon Dioxide Equivalent (CO 2 e)
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PWP Industries PWP Industries Major supplier of FDA Food Grade RPET Supplier of the 10% PCR PET for Subway June, ‘09 - opened 40 million lb. annual capacity PET Recycling facility in West Virginia at cost of $20M Second 40 million lb. facility scheduled to open Q2/10 in California Every 40 million lbs. of RPET represents elimination of 30,000 tons of CO2 and 398 million kilowatt hours … annually
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Integrated Packaging Films ECO-THERM tm 100% Post- Consumer Recycled PET sheet Made with FDA food contact RPET resin
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Preserve Preserve toothbrushes made from 100% Post-Consumer Recycled Polypropylene (PP) - Yogurt Cups Packaging Clamshell made by Innovative Packaging from ECO-THERM tm 100% Post-Consumer Recycled Content PET Preserve’s Claim: “Plastic packaging made from 100% post- consumer plastic bottles”
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Schering-Plough, Corp. OTC offerings include Claritin allergy pills, Afrin nasal sprays, Dr. Scholl’s foot care products, and the sun care line Coppertone Products marketed in some 140 Countries Company has agreed to be acquired by Merck
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Schering-Plough, Corp. New Package Requirements: Must work in “Club Store” setting Sustainable material Does not require the purchase of Sealing Equipment
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XO Athletic Company Over 20 Years experience in the Sports Medicine market Supplying over 80% of the US athletic cup market Invented the “flexible cup” in 2000 – hard cup covered in soft rubber
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XO Athletic Company New Package Requirements: New, smoother design that is more in line with product Clamshell Does not require the purchase of RF sealing equipment and can be packaged “in house” More Sustainable material
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XO Athletic Company Packaging Development: June 2009: First Choice met with CardPak and LucDesigns Engineering, LLC. to discuss XO Athletics’ concepts
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XO Athletic Company Packaging Development End of July 2009: Presented full display planogram to major retailer Sept 2009: Moving forward on production order for Fall 2009 introduction
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NEW PACKAGING FOR 2010 XO PROCUP Current New XO PROCS2 CurrentNew
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ScarGuard Labs, LLC, Inc. A Pharmaceutical Company guided by Doctors, Pharmacists, and Pharmaceutical Biochemists with decades of combined experience Manufactured in three locations across the U.S. ScarGuard MD and ScarLight MD available at Doctors’ offices and Retail Outlets (CVS, Walgreens, etc.)
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ScarGuard Labs, LLC, Inc. New Package Requirements: Eliminate material splitting More Sustainable material Improve product fit Lower Costs
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ScarGuard Labs, LLC, Inc.
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Retailers’ Imperatives Retailers’ Imperatives Desire to provide Value to Consumers leads to constant pressure on Consumer Products Companies for lower and lower prices Pressure from Environmental groups for major Retailers to act as quasi- governmental bodies by setting Sustainability standards Opportunity to work with Recyclers on Closed Loop Recycling Programs to increase Post-Consumer Content
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Retailers CharacteristicPVCPLAPETRPET Environmental NoNoNoYes Claims can be Substantiated Cost EffectiveMostNoYesYes Can SurviveYesNoYesYes Distribution
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Recyclers’ Imperatives Recyclers’ Imperatives Need to have a Critical Mass of packages in a recognized Recycling group to make it profitable to separate Need to have a minimal number of packages in the Waste Stream that contaminate the Recycling System, eg., PVC or PLA Opportunity to test PET, PP and PS Recycling Programs with companies like A Greener Solution or NextLife
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Recyclers
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Continued Improvement in Physical Characteristics and Performance Continued Availability of PCR Resins … esp. FDA Food Contact RPET … Large potential Source: 166 Plastic Bottles per year … but only 20% are presently recycled Claims can be readily Substantiated … and meet “Truth in Labeling” Mandates Potential for Increased Government Legislation
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Consumers recognize that Recycled Content Packages have positive environmental impact Continued comfort with “Post-Consumer Recycled Content” Claims … even on Food Packaging Continued Support by Major Retailers and CPG Companies Opportunities for PP and PS Recycling … with companies like A Greener Solution or NextLife Continued Competitive Cost
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Jim Scott, Principal JES Packaging (401) 597-0761 jamesescott@cox.net
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