In This Chapter
Because packaging our products consumes a lot of paper, plastic, and energy, it presents an excellent opportunity to reduce resources and cut costs. In the following pages, we’ll take a look at how your business can reduce the waste cycle and provide sustainable packaging that will cost less and benefit the environment.
The Sustainable Packaging Coalition is a project of GreenBlue, a not-for-profit organization working to educate businesses and the public about the importance of creating and utilizing packaging that is sustainable throughout its life cycle. The coalition defines sustainable packaging with these criteria:
Is beneficial, safe, and healthy for individuals and communities throughout its life cycle
Meets market criteria for performance and cost
Is sourced, manufactured, transported, and recycled using renewable energy
Maximizes the use of renewable or recycled source materials
Is manufactured using clean production technologies and best practices
Is made from materials healthy in all probable end-of-life scenarios
Is physically designed to optimize materials and energy
Is effectively recovered and utilized in biological and/or industrial cradle-to-cradle cycles
Wal-Mart is making a big difference in its environmental impact. As Newsweek reported (September 22, 2008), it has demanded its suppliers cut the cost of importing goods from China and other countries. By asking detergent suppliers to use more concentrated formulas and reduce container size, less petroleum is used and more containers can be shipped per carton. This also reduces cardboard packaging, allowing more containers to be shipped per truck and reducing the amount of fuel needed to bring the product to the retailer.
This kind of position taken by the world’s biggest retailer will affect small businesses as suppliers develop packaging standards that become routine procedures that affect the products and supplies you use, too. Be prepared for changes enforced by government and larger corporations by adopting a sustainable packaging strategy now.
For decades, plastic, cardboard, Styrofoam, and paper have commonly been used as packing materials. In developing more sustainable packaging, the first line of defense is to reduce the amount of materials. By using sustainable materials, we can preserve the packing and shipping resources we use. Developing a sustainable package design at the outset of product development—instead of as an afterthought—can maximize environmental benefit. Remember to consider the energy expense of creating materials and the waste impact of materials to find the best balance of cost-effectiveness and sustainability.
Earth Policy Institute reports that packaging uses 7 percent of the food-related energy produced in the United States, and if you’re a food business owner, the cost of that energy is contained in your packaging processes. Packing for other products is also energy intensive. You can reduce this energy expense and its attendance emissions by developing more sustainable packaging for your products and purchasing sustainably packaged supplies.
The Environmental Protection Agency (EPA) reports that corrugated fiber and plastic packaging made up about 25 percent of discarded packaging materials in 2000. In 2006, paper products amounted to 85 million tons of waste, 40 percent of all municipal waste.
Plastic and Styrofoam, both produced using potentially toxic synthetic petrochemicals, contribute greatly to our waste problem because they don’t break down but instead pile up in landfills and fill our oceans with dangerous detritus. Fortunately, the plastics industry is beginning to understand the need to develop comprehensive recycling programs for difficult-to-recycle plastics and is educating consumers and producers on the importance of proper end-of-life disposal for all types of plastics. If you choose to use plastic packaging, choose a type of plastic that is easily recyclable in most municipal waste collection streams, such as #1 (PETE) or #2 (HDPE).
Paper-based packing materials, including cardboard, represent a substantial use of trees for materials typically disposed of after a single use. The GreenPostalStore.org, which offers eco-friendly packaging materials, says the United States destroys 200 acres of trees each day for packaging materials and throws 200 tons of plastic packaging away. We can do better than this!
Cardboard and paper are biodegradable, but let’s not send a good resource to the waste pile before it’s fully utilized. Let’s find secondary and further uses; simply reusing the packaging helps extend its usefulness.
Many companies are now designing biodegradable packing materials that can be composted into soil without leaving a toxic trace. From packing peanuts to molded recycled fiber containers, you can find ways to pack your product that will lessen its negative environmental impact on the planet.
Sustainability-minded engineers are designing differently shaped liquid containers that take up less space in shipping and often don’t require cardboard boxes; they can be loaded directly onto pallets and shrink-wrapped for secure shipping. In the GreenBiz.com e-zine (July 2, 2008), a Wal-Mart milk supplier reported that its new container can accommodate 224 1-gallon jugs in a space that previously carried only 80. The dairy estimates they’ve cut labor costs in half, decreased water use by more than 60 percent, and reduced deliveries to Sam’s Club stores from five times a week to two.
Green Packaging, Inc., a Pennsylvania-based company, specializes in providing sustainable packing materials to replace Styrofoam and plastics. They offer 100 percent recycled and recyclable packaging alternatives to peanuts and bubble wrap. They also carry recycled corrugated cartons, tissue paper, and paper tape. See Appendix B for contact information.
The common practice of tearing down cardboard shipping cartons for recycling is preferable to incinerating them, but it’s even better to reuse them.
Many shipping companies provide recycled and recyclable materials for clients. Even the United States Postal Service (USPS) offers eco-friendly packaging through its Priority and Express Mail services, which offer free flat-rate cardboard, envelopes, and boxes that have earned cradle-to-cradle certification for ecologically intelligent design.
Designing cartons we can easily disassemble and reassemble for reuse is a simple design change that can help continue the life cycle of the container beyond the recycling bin, saving energy and preventing pollution emissions.
Essential Design, a product design firm based in Boston, has produced an alternative packing carton called Treepac, made with cellulose acetate and designed for continuous reuse many times more than traditional cardboard packaging. The Treepac, which according to its manufacturer can be designed as a biodegradable product so it won’t contribute to landfills, won a Silver International Design Excellence Award in the Ecodesign category.
Printing instructions for the reuse of containers on the package (in nontoxic ink) can help consumers continue the cycle of sustainability by returning the container and packing to retailers for reuse instead of sending them to the waste system or recycling bin. Ask your packaging supplier if this type of consumer information is available on packaging you purchase to use for your business, or create a stamp, sticker, or package insert that can be applied during the packing process.
Another way to help your customer carry out your sustainability initiative is to provide a system for him to return materials and containers to you for reuse. Again, provide instructions for return in nontoxic ink.
According to the EPA, Americans recycle just 7 percent of the more than 200 billion pounds of plastic produced each year. The Green Postal Store says that 200 tons of plastic packaging materials go to landfills each day. Reducing the amount of plastic used in packaging can help reduce the plastic that goes to the landfills and also reduce toxic emissions from its production and degradation which pollutes our air, water, and soil. Reducing our use of plastic also reduces the amount of energy used to create it.
An alternative, sometimes called bioplastic, is being used for some food products such as coffee packages and water bottles. It is made with PLA (polylactic acid), a plant-based polymer said to be nontoxic and biodegradable. However, sustainability proponents have reservations about the product because it can still take up to 1,000 years to biode-grade and it’s often blended with plastic for the final product, reducing its sustainable value. In addition, it can be made from genetically modified plants, which have not received the green light of overall safety from environmentalists or many consumers yet (although genetically modified foods have been federally approved for use).
Going Green
Scientists at Clemson University announced in September 2008 that they’d developed the Earthbottle, a biodegradable bottle made from all-vegetable materials. Their company, Earth Renewable Technologies, is creating the bottle for Gaia Herbs as a container for herbal supplements. A good example of the emerging technologies that will help move us away from to more Earth-friendly packaging, the company says the bottles are stronger, lighter, and cost less to transport than plastic. They weigh about 20 grams each, compared to 115 grams each for the glass bottles the company now uses.
Shrink-wrap plastic has become popular as a means of ensuring a package has not been opened or tampered with. But weigh this concern against the environmental cost of producing plastic and disposing of it, and you’ll find it is sometimes unnecessary and more sustainable to avoid using shrink-wrap plastic on products. Some companies find that by securing materials to pallets with shrink wrap, they can eliminate excess cardboard boxes. This is certainly an area that will benefit from further development of green technologies and ideas for the best packing practices. Until a truly green choice comes along, you will need to weigh these options to determine the most cost-effective and eco-friendly choice for your company.
Plastic cases on packages are usually cut or broken off and disposed of in the trash or recycled as soon as the product makes its way home with the consumer. This represents unnecessary waste and produces piles of trash. Although we have established means for recycling plastic, a small percentage is actually recycled, so it’s better to avoid using plastic packaging material in favor of biodegradable or reusable materials whenever possible.
Molded fiber packaging materials are made with recycled paper products and can be form-fitted to your more sensitive products that need specialized cushioning for shipping. The molded fiber is nontoxic, biodegradable, and recyclable so it can remain in the useful cycle of sustainability. Several companies specialize in creating molded fiber packaging, including EnviroPak of Earth City, Missouri (www.enviropak.com), and UFP Technologies of Georgetown, Massachusetts (www.ufpt.com). You may wish to search out a supplier located near your place of business to reduce transportation cost for the packaging.
Biodegradable peanuts, which dissolve in water and are nontoxic, have been developed from corn starch, soy beans, and sorghum. They are lightweight and cost-effective when compared to traditional plastic-based packing peanuts.
According to TreecycleRecycledPaper.com, only a small percentage of used paper is recycled. We need to find more ways to recycle our paper products and to select paper products made from recycled paper whenever possible. Look for the Post-Consumer Waste (PCW) designation on the paper packaging materials you purchase, and make your customers aware of the importance of recycling the paper that comes with your products. Select unbleached paper materials—bleaching serves no functional purpose and yet the process contributes hazardous carcinogenic chemicals to many of our waterways. We can help reduce the impact of using paper products on our environment by choosing natural-colored, unbleached paper products.
TreecycledRecycledPaper.com recommends choosing paper labeled Process Chlorine Free (PCF), which means that it is recycled with no chlorine bleach or chlorine derivatives.
Some packing materials weigh more than others, and by choosing lighter materials, you’ll reduce the package weight and the cost of shipping. Plastic is usually heavier than paper or peanuts.
The best solution for reducing your environmental impact through packaging is to reduce your use of paper, plastic, and other materials. By consolidating your package to protect its contents in the smallest possible space, you’ll use less packing materials.
Pallets are a staple in shipping products, yet the wooden boards are often left to waste once the product reaches its distributor. Develop a plan to reuse your pallets so this resource can continue to serve your business long into the future; you’ll save a considerable amount of money on raw materials. The Rainforest Alliance promotes recycling pallets. Some enterprising businesses collect unwanted pallets, repair or dismantle them, rebuild them to make them sturdy, and then resell them.
Plastic pallets that have come on the scene are touted as more environmentally friendly than wood for two reasons. They are approximately 30 percent lighter than wood and therefore, require less energy to transport and they are recyclable, often being reground and cast into new pallets. As with many newly developed sustainable solutions, you need to weigh the options to find the best solution for your company and keep an eye on new developments that may offer better ideas.
The smaller your package, the less it will cost to ship. By cushioning your package in the most efficient way, you reduce package size and the cost of transporting it. If you can ship smaller packages, you’ll reduce the energy expended to get your product to its end destination and thus reduce your product’s carbon footprint.
Reducing package weight also reduces shipping costs. By using less packaging, lighter materials, and smaller containers, you’ll reduce your shipping expenses overall.
If you’re doing your own shipping, you’ll benefit from applying sustainable packaging principles to your products. Smaller packages with fewer, lighter-weight materials will make room for more packages in your shipping delivery vehicle, consolidating fuel expense and emissions.
Lighter loads also reduce fuel consumption, and if you consolidate shipping services by using smaller packages, you’ll reduce shipping trips and expenditures, as well as shipping emissions.
Reducing your shipping emissions means you’ll be reducing your company’s contribution to the pollution problem with fewer fuel emissions, less energy expended in the packaging materials and process, and less pollution generated thanks to using sustainable materials.
Evaluating your packing and shipping processes may result in saved resources and saved money.
Reducing use of unsustainable materials reduces your carbon footprint.
Helping customers reuse and return packing materials helps extend the life of the resources.
Using less material and reducing the size and weight of materials cuts costs and reduces emissions.