Multi-bottle beer pack

Transcription

1 Carbon Ready Reckoner Worked Example Multi-bottle beer pack This worked example shows how the WRAP Carbon Ready Reckoner can be used to provide insight into the carbon footprint of a multi-bottle beer pack Date: October 2013

2 Multi-bottle beer pack 1 Pack description Itemise and describe all packaging components. Consumer unit (primary packaging) The consumer unit is the packaging the consumer takes out of the shop. Some products are sold in collations, and the entire collation would be regarded as the consumer unit. This consumer unit consists of four packaging components: four amber glass bottles, 330ml; four steel crowns; 12 metallised paper labels (four neck labels, four front labels and four back labels) with full colour print; and a solid board sleeve with bleached, full colour printed outer. The WRAP Carbon Ready Reckoner does not assess minor materials, such as the adhesives, so these are not included. To calculate the impact of changes, the number of consumer units produced per annum is required. In this example, one and a half million packs of beer are sold per annum. If this pack format were used for a range of multi-bottle beer packs, then the total number of consumer units produced in the range could be included in the assessment. This multipack contains four individual bottles of beer (330ml each) and provides two servings each. Before removing the product it was noted that the head space was not excessive. Product information Information required Product weight per pack (g or ml) Existing pack 1320ml Servings per pack 8 Number of packs per year 1,500,000

3 Multi-bottle beer pack 2 Secondary packaging No secondary packaging improvements have been identified as no secondary packaging was available for the review. Palletisation The WRAP Carbon Ready Reckoner will calculate savings from improved pallet utilisation, but does not include savings from changes in tertiary packaging such as stretch-wrap, layer boards, and pallet top covers. Changes in size to the consumer unit and secondary packaging may affect the number of units that may be placed on a pallet or contained within another shipment unit, such as a Pal-box. Details of pallet configuration and transport will be needed to calculate distribution savings from reductions in pack weight. Packaging and transport data Packaging materials and weights Each packaging component is weighed to +/- 0.1g and the weight and material recorded as shown on the table below. Reference can be made to packaging specifications for weights, but actual pack weights should be checked. Consumer unit Glass bottles are manufactured using a number of moulds which wear with use. The average weight of the glass bottle was calculated from a sample of 24 bottles. As flint (clear), green, and amber glass have different recycled glass content it is necessary to note the glass type.

4 Multi-bottle beer pack 3 The crowns and the labels were relatively light and so it was calculated from the total weight of a batch of 50 components. The average weight of the sleeve was calculated from the total weight of a batch of 50. Existing components consumer unit Component name Existing material Current weight (g) Bottle (x 4) Glass-amber Crown (x 4) Steel 8 Label (x 4 sets) Other paper/card 2.4 Sleeve Cardboard 25.7 Secondary packaging No secondary packaging was available for the review of this pack. Palletisation and transport data This data is used to calculate the carbon impact of packaging changes on transport. The data required is outlined next.

5 Multi-bottle beer pack 4 Palletisation and transport data Information required Type of vehicle used for delivery Existing Rigid truck used most often capacity up to 17tonnes Average one-way distance to retailer or RDC (km) 150km Number of consumer units / carton N/A Number of consumer units per layer 86 Number of layers per pallet 4 Number of consumer units per pallet 344 (86 consumer units x 4 layers) Number of pallets per vehicle 16 As no secondary packaging was available, the number of consumer units on each pallet layer has been estimated based on the area of each multipack. In this case, it is assumed that 86 multi-bottle packs can fit onto a layer and stacked 4 layers high, thus 344 units are transported per pallet. A range of delivery vehicles are used to ship to various RDCs, so most typical vehicles were selected and average distances were calculated at 150 km (one way).

6 Multi-bottle beer pack 5 The vehicle options are limited to: van (less than 3.5tonnes load capacity); rigid vehicle (3.5 to 7.5tonnes load capacity); rigid vehicle (7.5 to 17tonnes load capacity); articulated vehicle (3.5 to 33tonnes load capacity); and articulated vehicle (over 33tonnes load capacity). In this case a rigid (>17tonne) vehicle is assumed. The number of pallets of this product that this vehicle will carry is 16. Pack improvements The WRAP Carbon Ready Reckoner will calculate carbon savings from various pack improvements. Each is considered as it applies to this multi-bottle beer pack. This pack was compared with other multi-bottle beer packs on the market. Some data on the WRAP UK Packaging Benchmark Database is available at: www2.wrap.org.uk/retail_supply_chain/research_tools/tools/uk_packagi ng_benchmark/index.html Packaging suppliers may be able to offer alternative pack options. Potential improvements to reduce carbon impact were considered for each pack component. The factors included in the WRAP Carbon Ready Reckoner are: packaging weight; product concentration number of servings/portions; secondary packaging or palletisation; glass: colour and/or recycled content; other materials: Recycled content and/or recycling rate; and other changes (listed at end of section).

7 Multi-bottle beer pack 6 Packaging weight Bottle: This bottle is one of the lightest in its class, and no improvement opportunity was identified. Crown: The steel crown is standard light weight. No improvement opportunity was identified. Label: The neck label could be eliminated as the information is repeated on the front and the back label. This will give an overall weight saving of 0.4g for the pack giving a new label weight of 2.0g. Sleeve: The sleeve is fairly light weight with minimal overlap and no improvement opportunity was identified. Product concentration number of servings No changes to the number of servings are proposed. Secondary packaging or palletisation No secondary packaging improvements were identified as there is no secondary packaging associated with this pack. Glass colour and recycled content Due to demand and availability of different glass colours, the recycled content of glass is Green (72.4%), Flint or clear (33.4%) and Amber (28.1%). It is recommended that the glass be changed from Amber to Green as this increases the recycled content of the bottle.

8 Multi-bottle beer pack 7 It is also worth noting that both Green and Clear bottles do not filter light as well as Amber bottles. Green bottles are suited to beers with little or no hops which are not as susceptible to damage from light. Other materials recycled content and/or recycling rate If higher recycled content is available for other materials (apart from paper and board) this may be used to calculate carbon savings. There is currently no facility within the WRAP Carbon Ready Reckoner to calculate the effect of increased recycling rate, such as bottles with a returned deposit value. Other changes No other beneficial changes to the pack were identified.

9 Multi-bottle beer pack 8 WRAP Carbon Ready Reckoner Data entry This section describes the process used to enter the previous figures from Existing and New packing components and calculation of the relative CO 2 eq impact. Logging in The WRAP Carbon Ready Reckoner was accessed via: and the correct Username and Password entered. A new project was created by clicking on the green button CREATE A NEW PROJECT. Definition A description of the pack being examined was entered, with sufficient information to ensure it is not confused with any other project. Under Which aspects of the packaged product are being changed? the box relating to packaging weight and product concentration/servings is selected.

10 Multi-bottle beer pack 9 The product measurement unit, weight, servings per pack, and number of packs per annum were entered under the Existing column as shown above. Click green SAVE button then move to next page: Consumer unit. Consumer unit This page allows the entry of consumer unit packaging components: Bottle, Crown, Label and Sleeve. Click ADD NEW COMPONENT button.

11 Multi-bottle beer pack 10 Enter a description of each component, current material (from drop down list); current weight, and new weight (as applicable) for each component as shown: When each component entry complete, click the green SAVE button. It is always possible to edit or delete components later. The figure for Current Recycled Content is automatically generated, but may be changed, except for paper and board components. When complete each entry may be viewed with the CO 2 eq figures already calculated. Even if there is no change in weight, all components should be included as they contribute to the final pack weight which affects the carbon impact of distribution.

12 Multi-bottle beer pack 11 Component entries may be deleted D or edited E using the small buttons on the right hand side. As the packs have no secondary packaging, the No radio has been button selected. Click Palletisation>> to move to the next page. If you wish to alter your selections it is possible to navigate by these buttons or via the top or bottom navigation bars. Secondary packaging As secondary packaging or palletisation box was not checked at the project definition page, this section has been excluded.

13 Multi-bottle beer pack 12 Palletisation This page allows the entry of changes in palletisation and calculates the carbon savings from any reduction in pallet numbers and the reduction in packaging component weights. The type of vehicle is selected from the drop-down box Rigid (>17t) and the one-way distance entered as 150km. The calculated number of consumer packs per pallet is entered as 344 and number of pallets per vehicle is 16 for the Existing pack. The values for the new pack are automatically updated and it is not possible to amend the values as secondary packaging has been excluded from the analysis. Clicking the green SAVE button will save these entries and calculate the carbon impact and savings in the yellow boxes.

14 Multi-bottle beer pack 13 To view the final results, click on the Results button on the right hand side to progress to the next page. Results This page shows the results of the calculations, and shows a 17.25% reduction in weight CO 2 eq. In this example, we have made changes to the packaging weight and the glass recycled content by changing from Amber to Green glass. The tick boxes above are a check of the improvements included in the calculations. The results below show the change in CO 2 eq between the Existing and New packs, and demonstrate in a pie chart the relative impact of different packaging components and transit.

15 Multi-bottle beer pack 14 Note that the weight packaging is now expressed in weight/cu (consumer unit or primary pack). Clicking on the Show difference on the top right hand side of the Consumer Unit table will show the calculated savings.

16 Multi-bottle beer pack 15 Before implementing any packaging change you will need to ensure that changes will not cause adverse effects during filling, processing and distribution. Pack image is always an important marketing consideration.

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