How to improve safe packaging disposal instructions

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Sybil Barrett
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1 G o v e r n m e n t C o n s u m e r S a f e t y R e s e a r c h How to improve safe packaging disposal instructions

2 C o n t e n t s p a g e Executive Summary i 1 Introduction 1 2 Objectives and scope 2 3 The issues Who is affected? Pack types involved Trends 4 4 Potential solutions Stop glass breaking Prevent sharp edges Provide disposal instructions 8 5 Recommendations 10 Executive Summary Of all packaging related-accidents, 39% occur in the after-use stage of the packaging life cycle. Two main packaging types feature, namely glass bottles and food cans. The majority of accidents involve cuts incurred from the sharp edges left by broken glass and on opened cans. Options for reducing the incidence of glass breakages are discussed including the use of coatings, labels, easy-to-grasp designs and alternative materials. The potential of plastic sleeve labels to contain broken glass is also discussed. While these may be technically feasible solutions, they are expensive and only generally economically viable for premium products. For high volume, low margin products/packaging such as milk, these are less attractive solutions. Where products can carry a premium, the incorporation of these design aspects should be considered. Options for reducing sharp edges on opened food cans are also discussed. Considerable technical challenges and cost premiums need to be overcome before solutions are available. However, the use of effective opening tools is advocated. The inclusion of additional disposal warnings/instructions on packs does not look to be greatly beneficial. The level of risk is not significant enough to warrant the inclusion of extra warnings/instructions. Also, manufacturers are already required to include increasing amounts of information on their packs. A real risk exists in consumers being subjected to an information overload. Such further information may well not be absorbed by many consumers. Appendix 1: Further reading 11 i

3 1. Introduction This report presents the findings of research entitled - How to improve safe packaging disposal instructions, part of the latest research into packaging-related accidents. The study involved: a review of the accidents data to determine the packaging types and principal accidents occurring during packaging disposal; a review of existing packaging disposal instructions, particularly for those packaging types most frequently involved in disposal accidents; identifying options for reducing the incidence of these accidents, especially safe packaging disposal instructions; generation and discussion of ideas with consumer panels and expert panels from the packaging sector. 1

4 2. Objectives and scope 3. The Issues The objective of this research was to examine disposal-related accidents and identify opportunities to reduce these accidents. As well as examining safe disposal instructions, wider issues of packaging design have been considered. Throughout the project, participation and input from industry has been encouraged so as to ensure that any potential solutions proposed are workable. 3.1 Who is affected? Table 1 below provides a breakdown of the incidences of packaging-related accidents by life cycle stage of the packaging within in the household. Table 1 Packaging-related accidents by life cycle stage (1994) Life cycle stage Number of Percentage of accidents# total accidents Initial opening 26, Re-opening/reuse 15, After-use* 26, Total 67, Source: Previous DTI packaging research conducted by Metra Martech * After-use accidents refer to all accidents occurring after the package and contents have been used # Number of accidents refer to the number of people reported to accident and emergency units 75% of all after-use accidents occur between the ages of 1 and 24, with men being 30% more accident prone than women. 3.2 Pack types involved Of the after-use accidents occurring, twice as many accidents occur during disposal (i.e. through carelessness) as after disposal (i.e. by someone injuring themselves on packaging discarded by someone else). Two main packaging types are dominant in the incidences of after-use accidents. These are glass bottles and food cans. To a lesser extent, accidents involving glass jars, pots and canisters also contribute to incidences of accidents during after-use. There are approximately 18,000 accidents per annum involving glass bottles. 84% of these accidents happen in the after-use phase. These include cuts occurring during the disposal of broken glass, cuts from broken glass whilst placing further items into the rubbish bag, and incidences of treading on broken glass (usually discarded by someone else). 69% of the victims of these accidents are under the age of 35 years and indeed some are very small children. In the majority of cases, the content of the bottle had not been specified, but where it had it is reported that milk bottles are a high proportion, including incidences of people tripping over them on the doorstep. Glass milk bottles were involved in over 3,000 cases. Perfume bottles were involved in around 1,500 cases. 29% of food can accidents (excluding corned beef cans) occur in the after-use phase. Almost all these injuries relate to cuts to the hand. In total, there are approximately 28,000 accidents involving tins per annum. 2 3

5 4. Potential solutions It is not possible to deduce from the existing accidents data whether any of the current incidences of after-use accidents are associated with cleaning and sorting activities within the household to facilitate recycling. Given that the main pack types involved are glass bottles and food cans, it is possible that these activities contribute to after-use accidents, though it is not possible to estimate any degree of importance. 3.3 Trends Between 1991 and 1994 a slight increase in incidences of accidents related to glass bottles was recorded. During this period no change in the incidences of accidents involving food tins was recorded. An increasing emphasis is being placed upon the recovery and recycling of packaging waste in the UK. This is being driven by legislative requirements (principally by the EU Packaging and Packaging Waste Directive). This is likely to lead to increased handling (eg washing, sorting, crushing) of consumer packaging waste, including glass bottles and food tins, by both the consumer and by the waste management worker. This may increase the potential for after-use accidents, particularly for glass bottles and food cans. Milk bottles have been highlighted as a potential source of accidents. Milk in the UK is traditionally delivered daily to the doorstep in glass bottles. Empty milk bottles are left on the doorstep for collection and reuse. Glass bottles are best suited to this reuse system. In recent years this method of distribution has declined in popularity. Milk is now frequently sold in retail outlets. This change in distribution patterns has necessitated a change in packaging requirements. Milk sold through retail outlets is commonly packaged in composite cartons or polyethylene terephthalate (PET) bottles. These packaging solutions are more appropriate to the one trip system of the retail outlets. The Dairy Industry Federation believes that doorstep deliveries have already reached a plateau. However, should doorstep delivery decline further, we should expect to see a reduction in the number of accidents involving milk bottles. A key objective of this research was to identify opportunities to reduce the incidences of accidents occurring during the disposal of packaging. The accidents are caused principally by the sharp edges presented by broken glass and opened food cans. A number of opportunities for reducing the incidences of these accidents are discussed below. 4.1 Stop glass breaking A large proportion of the accidents are caused by broken glass. If the initial breakage can be eliminated, then the accident can be prevented. The dynamics of glass, particularly when it breaks, are not clearly understood, but a number of solutions can be suggested which may help prevent breakages. These issues are also addressed in DTI s research report Examination of ways to reduce injury from glass packaging published in parallel with this report Coatings A contributing factor to breakages is the fact that glass is smooth and can therefore be difficult to grasp, particularly when condensation is present (eg when removing bottles from the refrigerator or collecting bottles from the doorstep). Coating is an integral part of the bottle manufacturing process. Potential exists to include an additional coating step that provides a non-slip surface. Currently, some decorative coatings may incidentally provide a less slippery surface. However, currently these coatings are expensive, and are therefore only attractive for high value products such as alcoholic drinks. For low margin products, such as milk, costs make this a less attractive option Labels The functions of labelling are traditionally the provision of information to the consumer and decoration. In the glass bottle sector, the label may also provide a holding area which is less slippery than the underlying glass. Most products bottled in glass already incorporate some form of labelling, most commonly as wet glue labels, self adhesive paper labels or as plastic sleeves. It is very likely that without existing labelling the number of accidents would be much higher. Designers should consider the function of the label as a holding area as an integral part of the packaging design process. This will ensure that labels provide an adequate surface for grasping in terms of size, location, and label material used. Few glass bottled products do not include labels. Milk is the notable exception. The addition of the label would increase the packaging costs and would also complicate the reuse loop. Additional processing at the reuse stage may well be required to remove the label. However, if such problems could be addressed, there may well be scope to reduce accidents with milk bottles Graspable designs Bottle designs can be shaped to provide a certain amount of intrinsic grasp. For example, they can have a waist or finger panels. Many bottle designs already incorporate design characteristics which provide users with shaped holding areas, these may include embossed labelling. 4 5

6 Bottles incorporating such designs can be more expensive and technically more difficult to produce than plain bottles. Some bottles are traditionally simple, for example the traditional wine bottle or the standard Boston round. Consumers recognise these classic designs and associate them with a particular (quality) product. Changing the bottle design is unlikely to be favoured by marketers or consumers, and would also present technical and financial difficulties as traditional equipment and distribution systems would need to be replaced. Bottle redesign to include graspable features is not an attractive option for most high volume or low margin products. However, for higher quality products which incorporate embossing as part of their design and decoration, consideration should be given at the design stage as to how this decoration may assist in holding the product Alternative materials Glass could be replaced as a packaging medium with materials which do not present a hazard when dropped, such as carton board, plastic or cans. In many cases, for example in the case of carbonated drinks, cans and plastic bottles have already replaced glass bottles. It is theoretically possible to replace virtually all glass bottles for fast moving consumer goods (fmcg) with plastic alternatives. However, replacing the existing infrastructure would be a costly exercise and the economic and social impact to the glass industry would be very significant. Consumer attitudes must also be considered. The public like glass packaging. Its weight, look and feel convey a sense of quality, and consumers expect certain products, such as wine or spirits, to be sold in glass. Also, there are environmental considerations. Therefore, a total elimination of glass bottles is not likely to be an acceptable option. However, where appropriate (technically, economically and in light of consumer demands) manufacturers should consider alternative packaging media. Milk in the UK is traditionally delivered daily to the doorstep in glass bottles and empty milk bottles collected for reuse. Glass bottles are well suited to this reuse system, but milk sold through retail outlets is commonly packaged in composite cartons or PET bottles. 4.2 Prevent sharp edges When glass breaks, it becomes a hazard because the fragments have sharp edges. When cans are opened, sharp edges may be produced. It is these sharp edges which are causing accidents. If the sharp edges can be eliminated, accidents can be avoided Glass Shatter proof glass It has been suggested that shatter proof glass, such as is used for car windscreens, might be used for glass packaging. The cost of this is extremely high. The result would be that industry would have to pass on the cost to consumers, which is likely to meet consumer resistance. Plastic sleeves A more viable solution may be the wider use of plastic sleeving on glass bottles (see photo). Plastic sleeves are now commonly used in the packaging industry, especially for products such as carbonated drinks. The plastic sleeve is shrunk to fit tightly to the bottle. Plastic sleeves provide excellent labelling media. They allow all over coverage of the bottle with high quality print opportunities, whilst also facilitating tamper evidence as they can be shrunk to cover the closure as an all in one sleeve. It has been suggested that a shrink sleeve may protect a bottle on impact to prevent breakages or the sleeve may contain the shards when a bottle is broken. This may help to reduce the number of accidents caused whilst people are cleaning up broken glass. Shrink sleeves are less likely to be an economically viable option for all glass bottles as they will incur an additional cost of several pence per bottle, in some cases at least doubling the cost of the packaging. However, this option does look attractive for high value products Cans Sharp edges can be left when cans are opened. This applies to traditional three piece cans opened with a can opener and both two and three piece easy open end cans. These issues are addressed in detail in the parallel report Improvements in design of metal packaging containers for easier opening and less hazardous disposal. Alternative materials for cans It has been suggested that aluminium cans/can ends, particularly for easy open ends, may leave a less sharp edge than traditional steel/tinplate ends because aluminium is a softer metal. However, aluminium is currently more costly than steel/tinplate, and can suffer from product incompatibility problems. Also, aluminium cans may leave sharp edges when crushed for recycling, which could contribute to further disposal-related accidents. Plastic cans and can lids have found some applications in recent years (eg for DIY products), but often these cans cannot fulfil the needs of the food industry as they cannot withstand retort heat and pressure. The technical challenges and considerable cost premiums mean that aluminium cans and plastic cans are unlikely to provide an effective solution to the problem of sharp can edges in the foreseeable future. 6 7

7 Encourage the use of effective opening tools Effective opening tools are less likely to leave dangerously sharp edges than old or ineffective ones. People frequently use the same tin opener for many years without sharpening or replacing it. Grease and other matter may accumulate in the works to reduce the effectiveness of the opener. Members of the public should be encouraged to replace old and ineffective can openers with the more effective can openers now available on the market. These new tools should be appropriately maintained (cleaned and sharpened) and replaced when no longer serviceable. Issues relating to opening tools are discussed in detail in the parallel report Use and misuse of package opening devices. 4.3 Provide disposal instructions Providing the public with packaging disposal instructions is a potential solution. If the public are more aware of the dangers that packaging presents when it is disposed of or discarded, they may be more likely to take appropriate precautions Public education A public education campaign may raise public awareness of the hazard presented by broken glass and opened cans. This may take the form of a safety advice, perhaps contained within editorials in widely read magazines. Contents of such material should cover: safe handling and disposal of broken glass; safe opening of cans (i.e. use of appropriate tools), safe handling and disposal of opened cans; safety for recycling; reminders not to discard packaging (glass and tins) in public places; what to do should an accident occur. Safety information in this form may be more effective in raising public awareness of the issues than on-pack instruction, and will also avoid the problems of information overload on packaging labels Disposal instructions on packaging As part of this research, a review was undertaken to determine whether disposal instructions are displayed upon existing packaging and packaged products. It was found that disposal instructions are very rarely included. Those disposal instructions which were identified do not generally relate to public safety during disposal of the packaging. They generally relate to environmentally responsible disposal of the product and package (eg for the disposal of oil products). The exception is the warning on aerosol cans not to burn or pierce the can. It has been suggested that potential exists to include safe disposal information and other public safety warnings on packs, for example: Caution - broken glass cuts Beware - an opened can may have sharp edges This research shows that some consumers are unlikely to read all instructions on labels. There is also a risk that putting the blindingly obvious on labels could lead to other information being ignored. Therefore, the potential success of safe disposal instructions displayed on packs is likely to be limited. A clearer picture of how consumers dispose of packaging, along with the risks involved, is required before instructions on disposal are included on labels. Manufacturers are faced with an information dilemma. They are required to include increasing amounts of information on their packs, but the general public are being subjected to an information overload, and important messages may be going unread. 8 9

8 5. Recommendations Appendix 1: Further reading Recommendations for industry Packaging designers should consider issues of breakages and disposal as an integral part of packaging design. Where feasible, glass packaging should incorporate design aspects that assist the consumer in holding the bottle, such as waists, panels and appropriate embossing. Labelling should also be carefully considered. The position and material used for labelling may aid the consumer when holding a slippery bottle. Providing grasp should be considered as an integral function of the label. Manufacturers of easy open end cans should search for solutions to the problem of sharp edges left when the easy open end is removed. It is evident that the use of traditional distribution systems for milk (i.e. doorstep delivery of reusable glass bottles) has declined and may continue to do so. Plastic and composite carton single trip milk packaging from retail outlets will continue to expand. With this, it is likely that after-use accidents involving milk packaging will decline. However, if paper or plastic labels to assist grip could be added to milk bottles, there is likely to be an even greater decline in accidents. Industry should encourage consumers to use appropriate opening tools for cans, i.e. tools which will not leave sharp or jagged edges. Special offers and promotions may be used as an incentive by retailers such as free tools with reward/loyalty cards. Norris, Beverley and Wilson, John R, Designing Safety into Products - Making Ergonomics Evaluation a Part of the Design Process,, University of Nottingham, October Recommendations for Government With an increasing emphasis on recovery and recycling of packaging waste, the potential for after-use accidents may increase. Government should carefully monitor after use accidents data, both in the home and within the waste management industry. If it is shown that increased recovery and recycling leads to accidents, appropriate action should be taken. This may take the form of public education to reduce accidents in the home, and industry standards to reduce accidents within the waste management sector. Public education to raise awareness of the hazards presented by packaging when it is disposed of or discarded is also likely to be valuable

9 March 1999 Research commissioned by Consumer Affairs Directorate, DTI. Department of Trade and Industry 1 Victoria Street London SW1H 0ET Pira International Randalls Road Leatherhead Surrey KT22 7RU URN 99/622

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