1 Worked example using the after Lofthouse V., Trimingham R. and Bhamra T., 2007 In recent years, the environmental impact of packaging has become a prominent issue as it is a very visible product in the waste stream. The introduction of the European Packaging and Packaging Waste Directive in 1994, which requires Member States to ensure that all packaging placed on the EU market complies with certain essential requirements, has made packaging a more important issue for consideration in many businesses. The use of refillable packaging has long been cited as a possible solution to this problem, as illustrated by the support that two key British government organisations DEFRA (The Department for Environment Food and Rural Affairs) and WRAP (Waste and Resources Action Programme) are giving to research in this area at the moment. The use of refillable containers is not a new concept, and it is widely associated with the delivery of products such as milk, beer and fizzy soft drinks across Europe, and the Americas. The refillable packaging systems project aimed to identify green solutions for shower gel packaging. Below is a comparative LCA analysis using the MET matrix. The environmental performance of the original packaging and the new one is assessed over a 6 month period. Goal and scope of the study The main goal of the study is to identify areas of concern (e.g. materials), identify the associated life cycle stage and find solutions for a better design of the product to reduce the environmental impact. The need for the study comes from the EU packaging legislation as well as local legislation. The company wants to be in compliance and needs to know the results of the LCA study to make decisions regarding the new package design. The function of the product is to contain the shower gel. The functional unit: the amount of packaging needed for the amount of shower gel consumed by a person in 6 months. Original shower gel packaging Revitalising shower gel is currently supplied in a 200ml tube made from a blended polymer of 70% LDPE mixed with either HDPE or LDPE, which is extruded and heat welded (see the picture). The cap is injection moulded PP and is snap-fit. As the two parts cannot be separated, it is assumed that the whole packaging will go to after use. The 200ml tube lasts 20 washes. It is assumed that it will be replaced every month. The material flow diagram that represents this information is presented in Figure 1.
2 LDPE Bottle body production (Extruding) Ultrasonic welding Fill with product Transport PP Lid production (Inj. Moulding) Landfill Figure 1. Material flow diagram for the original packaging Inventory analysis The analysis is done using the MET matrix see Figure 2. The Material Cycle Energy Toxic Emissions Output Raw Material Extraction, Processing and Supply of Materials and Components Production Distribution Operation Total weight (tube and lid) = 0.034 x 6 = 0.204 kg 2 materials (LDPE 0.019kg; PP 0.015kg), oil based, nonrenewable, blended polymer. Cannot be separated, so cannot be recycled. Not hazardous. Not considered Not considered Negligible Not considered Wastes and emissions insignificant 6 trips transporting 0.232 kg per trip = 1.392 kg. Minimal secondary packaging, reusable pallets. Average 200km. Fuel consumed during transportation Emissions from transport include CO 2, NO X, Ozone
3 Service Recovery End of Life System Disposal All packaging to, no refill, repair, upgrade or recycling options Transport to site Additions to Figure 2. Analysis of original package using MET matrix Interpretation MET matrix is an abridged LCA tool that shows where the environmental problems of the current design are. As Figure 2 shows, the main problems with the original package is materials and materials usage. The other impacts on the environment derive from the materials choice and usage. Using the results of the MET matrix together with a DfE support tool, new solutions for packaging were found. Only ecodesign concept 1 (see picture) will be discussed here: Revitalising shower gel is supplied as a gift pack, which comprises a refill tub containing 3 x 15ml dissolvable sachets and 150ml empty pump pack. When the user gets the product home they put a dissolvable sachet into the empty pump pack and top it up with warm tap water to the line and then shake to mix. The concentrate makes 150ml of product. When the product is mixed it is dispensed via a pump which converts the liquid into a foam. Dissolvable sachets The dissolvable sachet is a cast film of oil based PVOH, it is then heat sealed. The refills weigh 10.5g full and 0.5g empty. Refill tub The tub that contains the refill has a recyclable injection moulded PET base and a lid made from 100% recycled stamped aluminium, the assumption was made that this would not be recycled due to lack of facilities. The base of the tub weighs 19g 3, the lid weighs 8g. Pump pack The 150ml pump packaging which comprises of a recyclable injection moulded PET bottle, a PP lid and a pump which is made from a mixture of materials (steel 10%, PVC 10% and PP 80%). The empty pump packaging weighs 58g (it is transported empty). Due to the foaming effect a 150ml pump bottles lasts 50 washes. It is expected that it will be refilled every 2 months. An analysis of ecodesign concept 1 using the MET matrix is presented in Figure 3.
4 The Material Cycle Energy Toxic Emissions Output Raw Material Extraction, Processing and Supply of Materials and Components Production Distribution Operation Service Packaging weight for 1 pump & lid, 1 tub & lid + PVOH film = 0.082kg. 0.047kg can be recycled 0.038kg goes to. Tub lid is recycled aluminium. Not considered Not considered No sterile water Not considered Wastes and emissions insignificant 1 trip weighing = 0.1298kg (1 empty pump bottle @ 0.058kg + 3 dissolvable sachets - 0.0015kg x 3 + 1tub and lid @ 0.0198kg) Average 200km. Fuel consumed during transportation (less no. of trips) Emissions from transport include CO 2, NO X, Ozone (less no. of trips) End of Life System Recovery Disposal 55% of weight is recyclable (PET pump and tub base), leads to less than original. Tub can be reusable The rest goes to Transport to site (only 45% goes to ) Additions to (only 45% goes to ) Figure 3. Analysis of ecodesign concept 1 package using MET matrix
Comparing the weight of product and packaging required to package 6 months worth of energising shower gel: futuresme 5 Weight = 0.1298kg Weight = 1.392kg Comparing the amount of waste material generated by the consumer after a 6 month period: Weight = 0.038kg Weight = 0.204kg Summary of improvements attained through package ecodesign concept 1 Original design Ecodesign concept 1 Total weight of material 0.204 kg 0.082 kg % weight reduction of 59.8% materials Total weight for transport 1.392 kg 0.1298 kg (including the shower gel) % weight reduction for 85.38% transport Total weight of material to 0.204 kg 0.038 kg % weight reduction of 81.37% materials going to Total weight of material that can be recycled 0 kg 0.047 kg