Footprint with Sustainable Packaging January 2007
At DuPont, our vision is to be the world s most dynamic science company, creating sustainable solutions essential to a better, safer, healthier way of life for people everywhere. Throughout our history, we have continued to challenge ourselves with this question: Are we helping to solve the world s toughest problems and building a brighter future for people and our planet? Pressure from consumers for socially responsible corporate behavior; the rising cost of petroleum and raw materials; and pollution controls and compliance issues have all led to the revamping of corporate agendas. Resources that once seemed infinite and that are so heavily relied on are being depleted at an extraordinary rate. A generation ago, business fundamentals focused on functionality and cost competitiveness. While the cost fundamental is still paramount, today s corporations are developing sustainability goals that aim to reduce the environmental footprint throughout the global value chain. These mandates create a number of opportunities for packaging decision makers. While the packaging industry has made great progress in reducing its environmental footprint, it is widely recognized that there is still much to do. As a result, key stakeholders in the industry must help to bring more sustainable packaging practices to fruition. While this may seem like a daunting task, many in the industry have taken an incremental approach, implementing solutions as they become practical 2
from a production standpoint. One critical step in the right direction is the use of renewably-sourced packaging packaging composed in whole, or in significant part, from annually renewable bio-based feedstocks that have as little impact on the global environment as possible. Over 2000 years ago, the Chinese first developed bio-based packaging to wrap fresh foods, using sheets of treated mulberry bark. These early packages offered functionality and performance. In the centuries that followed, the slow development of packaging science was dedicated almost solely to the preservation of fresh food for later consumption. The fact that societal resources were finite and that human activity indeed had an effect on the environment would not be realized for hundreds of years. While society was slow to recognize the importance of environmental conservation, the 1920 s brought about a transition in the world of packaging with the emergence of polymer science and with it, petroleum-based plastics. Plastics brought a level of functionality to packaging that had never been achieved before. The polymer industry experienced an exponential business increase, developing into one of the world s largest industries. It wasn t until the late 1960s and early 1970s that the general public began to realize the importance of conservation. In July of 1970, the law that established the U.S. Environmental Protection Agency (EPA) was passed in response to public 3
demand for cleaner water, air and land. Throughout the 1970s, we began to see a growing public interest in environmental concerns, highlighted by the emergence of recycling, and the advent of bio-based and renewably sourced materials. By producing materials derived from plant sources such as hemp oil, soybean oil and corn starch, manufacturers were able to find a sustainable way to create products that had, albeit for small size applications, promising properties when compared to the petroleum-based plastics. The packaging industry quickly took note. Advantages of Renewably-Sourced Packaging The overarching goal of renewably-sourced packaging is to provide a material that has little or no impact on the environment while providing cost and performance parity with petroleum-based counterparts. The term renewably-sourced does not equate to biodegradability or compostability, but instead to the source of the raw materials that are used in the production of the product. According to the EPA, it is estimated that the U.S. produces around 250 million tons of solid waste per year 35 percent paper material, 11 percent plastics, 8 percent metal and 5 percent glass. Recycling programs and composting have helped curb the total amount of waste, but the majority continues to be sent to landfills. By creating a product that is biodegradable and compostable, packaging scientists and executives can greatly reduce the amount of waste produced, while minimizing or completely eliminating recycling costs. 4
Cost continues to be an important consideration for consumers as well as converters and brand owners. Petroleum-based packaging still provides greater performance at lower costs, although the rising cost of petroleum has reduced the price differential with renewably-sourced packaging. A September 2005 survey conducted by Ipsos Public Affairs found that consumers are willing to pay more for improved packaging that ensures freshness. Seventy-two percent said they would pay at least 10 cents more on a $3 item, while 35 percent said they would pay at least 25 cents. But while product freshness continues to rank higher than environmental protection on the list of consumer values, it is likely that as the cost-gap between petroleum-based and renewably-sourced packaging shrinks, consumers will be more willing to pay those extra few cents for the satisfaction they receive from doing their part to help the environment. In the food and beverage industry, we have seen a sharp increase in consumer demand for organic products with no preservatives, chemicals or additives. This is accompanied by a demand for eco-friendly, sustainable packaging. This has not only caused brand owners to introduce more of these products and packages to the market, it has provided them the opportunity to differentiate themselves from competitors creating a point of difference by showing concern for the environment provides a marketing edge. By introducing products and packaging that reduce their environmental footprint, brand owners help increase brand loyalty while fulfilling the demand for socially responsible corporate behavior. 5
Challenges of Renewably-sourced Packaging The use of renewably-sourced materials for packaging is slowly gaining momentum. While technology continues to improve in conjunction with sustainability awareness, renewably-sourced packaging still faces a number of challenges. Packaging executives understand that consumers have a choice. Consumers are looking for innovative packaging technology that offers safer, fresher, healthier food, more varied choices, and greater convenience and flexibility. Unfortunately, many renewably-sourced materials used in packaging have limitations that can have a serious impact on performance. PLA (polylactic acid) for example, is rigid and has a tendency to become very brittle. There are also limitations on thermal stability PLA requires humidity below 50 percent and temperatures under 105 Fahrenheit. The challenge then lies in creating a product that fills these performance gaps while remaining cost-effective. With just about any new innovation or technology, it can take many years to perfect the process. As we have seen with packaging technology, it took centuries to move from mulberry bark casings to modified atmosphere packaging. Although there are limitations to renewably-sourced materials, manufacturers are working tirelessly to bridge the performance gap. 6
Emerging Interest in bioplastics such as PLA, continues to grow in the packaging industry, in large part due to its compostability and renewable content. It is believed that the manufacturing process of bioplastics requires significantly less fossil fuel than traditional plastics and the field corn used in its manufacture is annually renewable. Recognizing the importance of PLA as a sustainable alternative to petrochemically derived products, DuPont developed Biomax Strong, an additive (called a modifier in the industry) that improves the toughness and reduces the brittleness of PLA materials. Biomax Strong enhances the impact strength, flexibility and melt stability of PLA with limited effect on transparency, particularly when used in rigid applications like cast sheets for thermoforming and injection molding. It s important to note that Biomax Strong Modifier is different from Biomax 4024 & 4026 Compostable Resins, which are mainly used in extrusion coating (onto paperboard) for packaging applications. DuPont Sorona Polymer, another renewably-sourced material from DuPont, is an innovative polymer that can be adapted to a number of end use applications. Typically used in the apparel industry in the form of fibers and fabrics, renewablysourced Sorona can also be employed in making films, filaments, engineering components, resins and more. When used in packaging applications, Sorona provides an excellent flavor and aroma barrier, while providing a better oxygen and 7
moisture barrier than PET (polyethylene terephthalate). In packaging applications, Sorona also offers outstanding clarity, printability and gloss. On The Horizon It s becoming increasingly clear that our world is too dependent on petroleum as a resource for fuels, chemicals, and other important materials such as plastics. There is a growing realization that to protect the environment, alternative sources must be found for the basic chemicals and materials that today are derived from petroleum. The development of bio-based and renewably-sourced materials, not only for the packaging industry, but across all industries, is simply one aspect of the solution to the complex issue of sustainability facing our world. DuPont s commitment to the packaging industry is to use its broad science and technology competencies to develop novel renewably-sourced materials that offer uncompromising performance versus incumbent petroleum-based plastics, at an attractive price. About The Science of Fresh Now more than ever, consumers expect safer, fresher tasting and more convenient foods - and food and beverage industry leaders are demanding ever-greater innovations in packaging technology that deliver on the promise of freshness. Through research and technological innovation, DuPont is constantly finding new ways to help make sure packaged foods stay fresh, pure and good tasting. From the strength, clarity and anti-leak performance of DuPont Surlyn, to the high performance broad temperature range adhesion of DuPont Bynel and the easy peeling, hermetic seals of DuPont Appeel, DuPont offers a complete line of highperformance polymers and additives to meet a wide range of packaging needs. For more information, please go to: http://www.scienceoffresh.dupont.com 8
About the Author:, CR&D Technology Manager of DuPont Experimental Station Dr. Arizzi is a Technology Manager in the Material Science & Engineering division of DuPont s Central Research and Development organization, in Wilmington, DE. His current responsibility is the development of innovative solutions for the food packaging industry including the development of biopolymers for packaging applications. He also manages the long range research portfolio for fuel cells at DuPont. He joined DuPont in 1991 at the European headquarters in Geneva. In 1996 he moved to Waynesboro, VA, to manage the new product development research of the Lycra business. Upon his return to Geneva in 1998 he became the Legwear global business manager. In November 2002 Dr. Arizzi moved to Wilmington to take the position of global technology manager for nylon polymer and Specialty Intermediates and finally joined DuPont s Central Research in 2004. Dr. Arizzi holds a chemical engineering degree from the Eidgenőssische Technische Hochschule in Zurich and a Ph.D. in chemical engineering from the Massachusetts Institute of Technology in Cambridge. 9
DuPont one of the first companies to publicly establish environmental goals 16 years ago has broadened its sustainability commitments beyond internal footprint reduction to include market-driven targets for both revenue and research and development investment. The goals are tied directly to business growth, specifically to the development of safer and environmentally improved new products for key global markets. The DuPont Oval Logo, DuPont, Biomax Strong, Sorona, Surlyn, Appeel, and Bynel, are trademarks or registered trademarks of DuPont. 10