Sustainable is Good | Where design, lifestyle and packaging meet

Five Steps Target is Taking to Reduce PVC Plastic

Last week Target, the nations fifth largest retailer announced a comprehensive plan to reduce and eliminate PVC plastic from its products and packaging. 

The announcement will have a major impact on Target's packaging operations where PVC is commonly used in clamshell type packaging.

Five Steps Target is Taking to Reduce PVC Plastic

• Reducing PVC in infant products and children’s toys:  All children’s eating utensils and lunchboxes are now PVC-free.  All baby bibs will be PVC-free by January 2008. The company is phasing out phthalates in most of their toys by Fall 2008.  They are also eliminating phthalates in baby changing tables by January 2008.

•  Significantly reducing PVC in shower curtains: They are significantly reducing their sale of PVC shower curtains by offering more shower curtains out of cloth and ethylene vinyl acetate (EVA), a safer PVC-free plastic.  They expect to be 88% PVC free by Spring 2008.

•  Reducing PVC in placemats, table linens, and coolers: Target will be 96% PVC-free in their placemat and table linen categories by Spring 2008.  All Target soft-sided coolers are now PVC-free.

•  Reducing PVC in packaging: Target is reducing PVC packaging in the company’s Target brand dinnerware, travel accessories, toys and sporting goods. For food packaging, Target has a requirement in place to avoid the use of PVC when possible.  In the media category (clamshells/blisters in electronics), Target is replacing the PVC clamshell with a modified paperboard/plastic packaging.  For instance, iPod carrying cases sold at Target are being packaged in PVC-free packaging.  The company is also asking their vendors to reduce the amount of packaging on their products and use materials that are easily recyclable.

•  Educating purchasers about PVC hazards: The company has developed a “sustainable products guide” that’s being “developed to educate internal product designers, sourcing specialist and merchants about sustainable products, and to help them identify suppliers who are committed to the principles of sustainable design. This guide addresses general principles of sustainable design and specific environmental considerations associated with forest and paper products and PVC plastics. It will be expanded in the future to address other product-specific issues.”

Visit the Center for Health, Environment and Justice's pvcfree.org web site for more information on their work in reducing PVC usage.

The "One Material Myth" vs. Environmental Reality

BY DENNIS SALAZAR

We believe that most companies could easily and inexpensively reduce the volume of packaging they use by as much as 15 to 20%. However, to achieve that reduction, companies must be willing to embrace the idea that the best and most cost effective solution may be a combination of packaging materials.

A Multi-Material Opportunity

For example, a worldwide manufacturer of inexpensive writing instruments recently asked us to help them create a greener and more sustainable package design to replace their rack displayed blister cards, which retail customers perceived as being environmentally unfriendly. The young and very talented project engineers had their hands full attempting to process and respond to the wide range - and often conflicting - input they were receiving from key retail customers and various departments within their own company. It seemed everyone had a different concept of the problem and the possible solutions.

One consistent message from the large retailers was a desire for unique packaging using less packaging material. I was confident we could help the manufacturer create a design to meet those demands, provided we utilize a combination of materials. An outstanding option immediately came to mind - a card and shrink film overwrap design, which we have been promoting as a blister and clamshell replacement.

When presenting our design to the engineers, I highlighted several important advantages.

•  By eliminating the blister sealing process, we utilize an uncoated card that is pre-printed with earth friendly and easily recyclable inks.
•  We gain the ability to imprint the cards on an as needed basis, providing flexibility while minimizing unique packaging SKU's, eliminating waste, and giving retailers the unique packaging they each
want.
•  By utilizing a cost reducing, polyethylene based, low energy shrink film, we are able to minimize the card thickness for easy package component separation and recycling.
•  Since no expensive tooling or mold charges are needed for our design, we eliminate capital investment and avoid the necessity of warehousing bulky blister or clamshell components.
•  No blister sealing means we eliminate the blister flange, allowing us to reduce the size of the display card, which in turn would result in smaller cases (less corrugated and sealing tape), and reduced fuel/freight costs.  A key additional benefit might be being able to place more product on the same planogram space allowed them by their customers.

After describing our design, one of the engineers stated that retailers did not necessarily want to make the overall package smaller, for visibility and security reasons. “Hmmm. Let me see if I understand, you want less packaging but not necessarily smaller packaging?”

Always appreciating a good challenge, I pressed on. Knowing how relatively slow and labor intensive clamshell and blister packaging can be and realizing the intense and increasing foreign competition my potential client was undoubtedly experiencing, I was glad to have saved a key advantage for the end of our discussion.

I informed them our concept would provide visibility, security, recyclability, and best of all, a package able to run at much faster speeds with less labor than their current design. Most package designers are focused on the way a package looks on the shelf but have absolutely no idea on how it is going to be produced in a plant environment. Our intimate knowledge of packaging equipment and processes helps us to maintain a dual focus on design and production. After all, what good is a “perfect” package design that requires twice as much labor and only runs at half the production speed of the current package being used?

The “One Material Myth” Perception rather than Reality?

We seem to have hit a package design homerun – less material, less labor, higher throughput, lower cost, greater flexibility, easy customization, superior shelf appeal, and reliable security. That is when one of the people mentioned their preference would be a new design utilizing only “one material” for ease of recycling and that they would prefer that one material used was not plastic.

Currently, the manufacturer is considering an all chipboard, die cut solution. To achieve the same retention and security, the design will require more chipboard than a board-shrink film combination. It will almost certainly require a coating making it less recyclable. It will offer less eye appeal, gloss, and sparkle than film would provide. It will do little, really, beyond fulfilling the prophecy of the “one material myth”.

Why Multiple Materials Multiply Benefits

Needs and objectives often conflict, but the fact is that in many if not most situations, two different materials working together, each bringing different characteristics and benefits to the packaging application, may be the best alternative. Many may not want to hear it, but shrinkable, forming plastic may be part of the solution from a performance AND from an environmental perspective. If they are easily separated and sorted, a combination of materials can help us reduce packaging by volume and by weight so that the people who chose not to recycle are doing as little damage as possible to the environment.         

Far from being an apologist for the plastics industry, I admit manufacturers and package design people can do a lot more than we currently are to minimize waste, but what we each decide to do at curbside on waste collection day is the ultimate unknown and one of the most important pieces of the sustainable packaging dilemma and solution. Why don’t more people recycle? That is a great question and the subject of my next article.

Dennis Salazar is the president of Salazar Packaging Inc., a certified MBE (Minority Business Enterprise) company specializing in flexible packaging products, equipment and solutions. After over thirty years in plastic film sales, he is the self-proclaimed, “Senor Shrink” of the industry and is known for his tongue in cheek sense of humor as well as his flexible packaging expertise.   
To contact, please email at: dennis@salazarpackaging.com

Wonder Tablitz Packaging

Massachusetts-based Wonder Tablitz has released a new packaging design for its line of household cleaning products.  The new packaging incorporates a custom designed patented empty spray bottle sold with three concentrated tablets housed within the bottle's design.   

A consumer would drop one of the tablets in the bottle through a special refill cavity on the backside of the bottle and add water making a full 32oz bottle of household cleaner.

The packaging design is being pushed as sustainable by the company because it says the fact its products ship without any liquid in them significantly reduces their weight and in turn the carbon footprint of the shipping/transportation process. 

The company also says its products reduce plastic waste by 66% because they come with three tablets or enough cleaner to produce three full bottles of product vs. having to buy three individual bottles of another brand.

Wonder Tablitz is the creation of the Schultz family, makers of the popular Gonzo line of household stain removers.  The products are available to consumers through hardware stores, grocers and other specialty stores as well as the company's web site. 

The new bottle design is receiving a fair amount of attention within the packaging community being recently covered in Pack World and on the Dieline.

Aveda Men Pure-formance

Pure-formance is a line of men's hair care products launched by Minnesota-based Aveda.  The line is unique and combines some of the company's best technology and innovation in its production and packaging. 

Aveda Men launched in July with seven hair care and styling products: Pure-formance Shampoo,  Conditioner, Composition, Grooming Cream, Grooming Clay, Liquid Pomade and Pomade.   

According to the company, each is formulated to suit men’s most important hair and scalp needs for maximum health, well-being, ease of use, and style.  The line is marketed as a series of products appealing to men's desires for both a healthy product and an environmentally responsible one.

Aveda Men takes on a new, edgy, masculine look with package design that is innovative, easy-to use and environmentally responsible.  Pure-formance Shampoo, Conditioner and Liquid Pomade are packaged in an industry-leading 95% post-consumer recycled HDPE (high density polyethylene).  Pure-formance™ Composition, Grooming Clay and Pomade are packaged in a carton made from 55% post-consumer recycled paper, printed with soy ink.  Pure-formance Grooming Cream is packaged in a tube made from 35% post-consumer recycled HDPE

We found Aveda's new men's line to be one of the best we've seen.  Several of our contributors examined products and packaging from the line and commented on the high quality and effectiveness of the product and the innovative unique nature of the packaging.  The shampoo and conditioner packaging are made from 95% post-consumer recycled HDPE plastic, which is impressive by any standards.  The design and shape of the bottles are well done, easy to use and highly effective.

Aveda Men is manufactured in Aveda’s primary manufacturing facility in Blaine, Minnesota, which now offsets 100% of its electric usage with certified wind energy.

Eneloop Rechargeable Batteries

Eneloop is a new line of smart rechargeable batteries from GE Sanyo.  The batteries are different than other rechargeables in that they are capable of holding 85% of their charge for up to a year and can be recharged 1000 times.  Eneloop batteries do not suffer from the "memory" effect that plagues many rechargeable batteries.  When recharged using Eneloop's chargers the batteries charge or lifespan is not adversely impacted.

The batteries come from Sanyo Japan and have been popular overseas.  Several minor changes were made to the product's packaging and design for the US market according to Sanyo USA's Stacy Rupert. 

The name "eneloop" came from Sanyo's Japanese HQ and stands for "energy in a loop".   Both the batteries and their PET plastic packaging are recyclable. 

Graphic design of the Eneloop line is exceptional and original.  The batteries are white and the brand name appears in blue.  Packaging is minimal and well designed for sleek slim shelf appeal.   "Both the battery and packaging were designed by our Japan HQ for the 2 pack, 4 pack, 8 pack as well as the Compact Charger & 4 position charger," said Rupert.  "We did do some in house modifications to it as well for the US market."  The modifications to the packaging include the addition of the orange band on the top of the packages which clearly explains eneloop is a rechargeable battery.

Several of the packages where designed exclusively for the US market.  "Our Power Pack design and USB charger packaging designs were done completely in house by our own graphic designer in our office," Rupert said.

Photo of eneloop's USA packaging courtesy of GE Sanyo

Clorox to Buy Burt's Bees

Oakland-based Clorox announced last week it will acquire North Carolina-based natural products company Burt's Bees for nearly a billion dollars.

Clorox produces a number of household cleaning products including its name branded bleach and Brita water filters.

Burt's Bees, which makes lip balm, lotions, hair products and other grooming items, is expected to have sales of about $170 million this year. The company was founded in 1984 in Maine, and is now based in Durham, N.C.

In addition to Burt's Bees focus on providing consumers natural products they have also been leaders in using eco-friendly packaging.  Most of their packaging contains high levels of post-consumer recycled plastic.  In its line of hair care products the packaging is made from #2 HDPE plastic containing 80% post-consumer content.  The labeling on many of the company's products contains the statement, "We take care of the environment in the choice of our packaging."

It is not known what impact, if any, Clorox's acquisition of Burt's Bees will have on their packaging.

Ditto Hangers 100% Recyclable Clothing Hangers

Oakland-based GreenHeart Global has developed what it believes to be the ultimate eco-solution to the massive problem of unrecyclable clothing hangers.  The company's Ditto Hangers launch today and are an innovative product with significant environmental benefits.

What makes Ditto hangers different from those currently available are the materials used to make them.  The hangers are made from two of the most recycled materials world-wide, paper and PET plastic. 

“We designed our hangers starting at the end of their useful life rather than from the beginning," said  GreenHeart Global President and CEO Gary Barker.  “That way we know they’ll have value on the secondary market, unlike the typical ‘invisible’ hanger found in most retail clothing stores”. 

Created for retail clothing companies, non-toxic dry cleaners and green hospitality Ditto Hangers are 100% recyclable in the majority of recycling programs at the store level. They are designed to replace the billions of #6 polystyrene (PS) and #5 polypropylene (PP) plastic and wire hangers that are produced annually, only 15% of which are typically recycled. The rest go to landfills taking over 1000 years to break down1 .

Ditto hangers has two product lines consisting of their 100% recyclable Ditto Paper Hangers, made from certified recycled paper (80-100% PCW) printed with vegetable inks and environmentally friendly starch adhesives, and Ditto’s 100% PET Plastic Hangers (min 70% PCW), the most highly recycled of all plastics world-wide.  Their unique design recently won two 1st prizes in the International Design Awards for Sustainable Living/Environmental Preservation and Urban Sustainable Design.

Barker explains, “Many clothing companies ship their clothing from overseas on plastic and wire hangers.  Once the item sells, the hanger is disposed.  So a hanger with a useful life of a week to a couple of months, ends up in a landfill taking 1000 or more years to degrade.  It doesn’t make sense.”

By focusing on making hangers made solely from either paper or PET the company can ensure the hangers are recyclable at end of life.  This is a major boon for their customers who can then turn around and cite their use of the product as an environmental improvement to their own customer base.

Interestingly the company considered producing Ditto hangers from bio-plastics, like the Merrick Earthsaver hangers Sustainable is Good has covered.  Ultimately they decided against it for a variety of reasons. 

"We, too, were hoping to use bio-plastics in our products," said Barker.  "However the more research we did, the more problematic the material appeared.  Corn based plastic is only compostable in municipal composting facilities with temperatures that reach 140º for 10 consecutive days, an environment not possible in home composting.  Most of the country does not have municipal composting programs.  Should bio-plastic get into regular plastic recycling it will foul the entire batch and render it unrecyclable.  If bio-plastic is not composted in a landfill will last as long as oil based plastic (1000+ years).  Corn used for PLA (NatureWorks) is genetically modified and uses more nitrogen fertilizer, synthetic fertilizers, more herbicide and more insecticides than any other US crop.  Sadly the time is not right for this new material. We hope in the years ahead, however, that it will be," said Barker.

Barker's new Ditto Hangers are not available directly to consumers, the company is focusing on clothing retailers, dry cleaners and the hospitality industry.

AlmaWin Cleanut Laundry Detergent

AlmaWin Cleanut is a natural concentrated laundry detergent from Germany.  The detergent's main ingredient is the soap nut.  Soap nuts have been used as a natural and healthy cleaning agent in India for over 3,000 years. 

Cleanut is based on soap nut extracts and blended with other ingredients in order to increase the washing power of those extracts.  The Cleanut laundry detergent fits in well with our recent focus on the growing trend in the US where many laundry detergent brands are offering concentrated versions of their products.

We found Cleanut to be a highly effective laundry detergent.  As we normally do the product was tested using a cold water wash cycle - which conserves significant amounts of energy.  Cleanut performed well in our tests leaving clothing and towels soft and clean.   

AlmaWin Cleanut exceeds the Belgian Ecogarantie standards. This independent label indicates that the production process and the Cleanut ingredients comply with the worldwide highest standards of sustainability and ecological responsibility.

Compared to American concentrated laundry detergents, Cleanut comes in a small 25.3 fl oz bottle and handles 25 loads of laundry.  For comparison purposes Unilever's All Small & Mighty standard bottle is 32 fl oz and handles 32 loads of laundry according to the company. 

Cleanut's packaging is a custom #2 HDPE bottle made by Rixius in Germany.

Cleanut laundry detergent is available in the US through Amazon.comin a case (6 bottles) or a package of two bottles.

Uncle Ben's Reduces Glass Packaging

Uncle Ben's UK division owned by Mars has recently launched a new glass bottle for its sauces.  The launch of the bottles follow a trial testing period and are supported by the Waste & Resources Action Program (WRAP) which is a UK government supported program focusing on the reduction of waste.

Published reports indicate Mars was able to reduce the weight of Uncle Ben's sauce jars by 6% which will save 450 tons of glass per year or 1,215 tons of CO2 emissions.

After initial testing and trials working with glass manufacturer, Ardagh Glass in The Netherlands, Mars set out to reduce the weight of its 258g ambient sauce jar.

Frieda Sporen, Mars’ packaging innovations manager, said: “This project, which saw close co-operation between our factory and our glass manufacturer, managed to reduce the weight of the jar to 243g.

“Crucially, the new jar can be manufactured smoothly on our existing production lines. It has meant the creation of new molds by our glass supplier and involved the slight increase in the diameter of the label recess area to create a smoother design, coupled with a slight reduction in the height of the jar. Together these innovations have delivered the lighter jar.”

Production of 30 million jars a year of Uncle Ben’s sauces will now switch to the new lightweight jar at the Mars factory in the Netherlands.

Mars recent achievement with its Uncle Ben’s sauce jar follows similar success in the reduction of the weight of its 500g Dolmio sauce jar last year.