ECOEMBES JORNADA TÉCNICA DISEÑA PARA RECICLAR MES DXR...•Conducting business in a responsible...

ECOEMBES JORNADA TÉCNICA

DISEÑA PARA RECICLAR

Lightweight primary packaging materials

Arno Melchior (Packaging Global R&B)

Jordi Jové (Packaging R&B España)

Barcelona, 15th November 2011

ECOEMBES JORNADA TÉCNICA

DISEÑA PARA RECICLAR

The journey to Sustainability

• 1823 – Benckiser started in Germany manufacturing ammonium chloride

• 1840 – Reckitt’s started in England producing starch

• A truly Sustainable company

Copyright © Reckitt Benckiser, 2010

Reckitt Benckiser

• World leader in household cleaning, health and personal care

>75% of net revenues from No. 1 or No. 2 brands

• Global reach

Operations in c. 60 countries, sales in c. 180 countries

c. 45 manufacturing facilities in 30 countries; 23,000 employees

Recent acquisitions

2006, Boots Healthcare International (e.g. Neurofen & Strepsils) c. £1.9bn

2008, Adams Respiratory Therapeutics Inc. (Mucinex) c. £1.1bn

2010, SSL (Durex, Scholl) c. £0.8bn


17 Powerbrands, all worldwide No. 1 / No. 2 brands

• Household

− Fabric Care: Fabric Treatment (Vanish), Water Softeners (Calgon), Garment Care (Woolite)

− Surface Care: Multipurpose Cleaners (Lysol, Dettol & Bang), Lavatory Care (Harpic, Lysol)

− Dishwashing: Automatic Dishwashing (Finish)

− Homecare: Air Care (Airwick), Pest Control (Mortein)

• Health and Personal Care

− Personal Care: Antiseptics (Dettol), Depilatories (Veet), Acne Treatment (Clearasil)

− Health Care: Sore Throat (Strepsils), Cough (Mucinex), Analgesics (Nurofen),

Gastro Intestinal (Gaviscon)

• Pharmaceuticals, Suboxone and Subutex

• Food Mustard, worldwide No. 1 – French’s

Reckitt-Benckiser España Main brands


Workplace

Marketplace

Community

Environment

What is “sustainability” for RB ?

• Conducting business in a responsible and ethical manner

• Managing our products whole value chain - from ‘cradle to grave’ - in an increasingly sustainable way

Sustainability has 3 legs:

− Social and ethical

− Environmental

− Financial


Marketplace

Marketplace – Ingredient Removal Programme


Environment

Energy Use

Waste Water

Environment

Operating today with as little adverse impact on the environment as practical Working to continually reduce our net environmental impact

Greenhouse Gas Emissions / Energy Use

• 30% reduction per consumer unit in CO2e from manufacturing energy use, 2000 - 07

• 21% absolute emissions reduction, 2000 - 07

Hazardous Waste

• 48% reduction in hazardous waste per consumer unit, 2000 - 07

• 21% absolute reduction, 2000 - 07

Water Use

• 12% reduction in water use per consumer unit, 2000 - 07

• absolute water use returned to 2000 levels in 2007, against market demand for liquids


• Concerned about environmental issues – 44% of consumers becoming more concerned about impact of household

products on the environment compared to a year ago

• Say they have 3 Big Problems re. climate change

– Feel that individually their actions won’t make a difference – Lack practical information on what to do – Environmentally better products are believed to cost more or not work as well

• Expect business to help them tackle these problems – They believe producers / manufacturers can make the biggest

impact on change along with Governments and much more than individuals, NGOs or retailers

Source: Ipsos MORI All UK adults April 2007; retailer / consumer interviews

Source: circa. 47 countries; AC Nielsen / University of Oxford, 2007

What do consumer feel / think about environmental issues / climate change ?

Source : Nunwood Market Research, 2007


a 20% reduction per unit in our products Total Carbon Footprint by 2020


What is a ‘carbon footprint’ ?

A measure of the IMPACT that a person / organisation /

product has on the environment in terms of CO2-equivalent

greenhouse gases (GHG) emissions, which cause climate

change


Raw & Packaging Materials

Product Manufacturing

Product Distribution

Retail Operations

Product & Packaging Disposal

Consumers

Raw materials and components

Packaging materials

RB Factories

3rd-party Factories

RB Offices & R&D Centres

Business Travel

Logistics Centres


Retailers:

- Logistics Centres

- Distribution

- Stores

Shopping journeys

Product use:

e.g.

- ADW

- Laundry

- Air Care

- Surface Care

- Hand washing

Product & Packaging Disposal / Recycling


• ca. 20 million tonnes of CO2-equivalents / year (2007)

= emissions from 3.6 million average UK households / year

= emissions from 5.7 million UK medium sized family cars / year

• a 20% reduction (c. 4m tonnes CO2e) equates to:

= emissions from > 0.7 million average UK households / year

= emissions from > 1.1 million UK medium sized family cars / year

Raw & Packaging Materials

Product Manufacturing


Product & Packaging Disposal / Recycling

Retail Operations

Consumers

HOW BIG is the Total Carbon Footprint ?


WHERE is the Total Carbon Footprint ? (2007 Data)

(2010 Data)


a 20% reduction per unit in our products’ Total Carbon Footprint by 2020

HOW will we do it ?!


• REDUCE energy consumption / improve energy efficiency - throughout the product lifecycle

• REPLACE ingredients, processes, packaging and energy sources - to continually move towards lower carbon alternatives

• BUT carbon offsetting will NOT be counted towards the Carbon 20 target. RB’s own carbon offsetting programme is planting over 4 million trees in more than 25 square kilometres of deforested land in Canada, offsetting emissions to be a carbon neutral manufacturer.

HOW will we do Carbon 20 ?!


The Plastic Packaging Recyclability Guide was commissioned by Recoup and was sponsored by Reckitt&Benckiser


Raw & Packaging Materials Less Materials, Less Energy, Less Waste

• In 2010, we sold >240 million bottles of liquid cleaner with a spray trigger a year

• Spray triggers allow consumers to apply products directly to the area that requires cleaning, optimising product use to the task required

• Working with Guala Group, who design and manufacture our spray triggers, we have developed a full plastic trigger and we will have in 2010:

− removed >670,000 kg of metal / year

− reduced >90,000 kg plastic / year

Guala Group’s TS3 Spray Cleaner Trigger

Benefit = 1,226 tonnes CO2e avoided, p.a.

= 220 households / 252 cars, p.a.

28.5 % Energy Reduction / Efficiency Optimised Materials Recycled Packaging Lower carbon materials & Packaging


Raw & Packaging Materials Less Materials, Less Energy, Less Waste

28.5 % Energy Reduction / Efficiency Optimised Materials Recycled Packaging Lower carbon materials & Packaging

Small savings can make a big impact In Europe we have changed the dosing scoop for Vanish powder from an injection moulded scoop to a thermoformed scoop. This change in manufacturing technology has reduced the weight by nearly 50% resulting in 153 tons of PP resin saved. As the thermoforming process requires much less energy than injection moulding this project also saved around 638 metric tons of CO2.

Thermoformed scoop Injection moulded scoop

A real life example

Vanish Powder Offer a flexible pack along the rigid container

• We decided to offer a ECO variant of our Vanish fabric treatment powder

−Ecological: improved package/product ratio => much less packaging weight per 100g of powder

−Economical: cheaper per 100g than the product in the tub

• During and especially after the project we had to answer many questions were the solution was neither black nor white

Score 0:1 Vanish Powder Offer a flexible pack along the rigid container

• Packaging weight 78g • Packaging weight 18g


• Packaging weight 78g

• Packaging weight 18g (not recycled)

• But the container is recyclable and the flexible-pack is not!

Score 1:1


• Packaging weight: −Container 52g (partly recycled)

−Lid 22g (not recycled- in the UK)

−Label 4g (not recycled – in the UK)

−Already a total of 26g which is not recycled at all


• But the container is recyclable and the doy-pack is not!

Score 1:2


• Packaging weight: −Container 52g

−Typical recycling rate for plastic bottles in the UK ~ 40% (2009)

−This means: 21g of this tub are recycled and 31g are not recycled


• But the container is recyclable and the doy-pack is not?


• Recycling:

• 57g which are not recycled

• 21g which are recycled

• Recycling:

• 18g which are not recycled

• But the container is recyclable and the doy-pack is not?

Score 1:2

• What about carbon emissions?

• Nearly 4x higher for tub


−Container 52g HDPE ~ 165g

−Lid 22g PP ~ 73g

−Label 4g Paper ~ 7g

−TOTAL ~ 244g CO2e

−Flexible Pack 18g Laminate =

−TOTAL ~ 63g CO2e

Score 1:3

Score 1:3

• Line speed per minute if 1kg of (dusty) powder is filled:

• For one tub line we would need FIVE flex-pack lines!!!


• Theoretically 120/min

• Practically ~80/min

• Theoretically 35/min

• Practically ~16/min

Score 2:3

• Delivery of empty packaging material:

• Transport volume for empty tubs is 65x the one of doypacks


• 4800 tubs each 11.2 x 11.2 x 14.5cm = 8.7m3 plus 1.9m3 for lids + labels

• Total = 10.6m3

• 4800 packs on a reel 50x50x65cm = 0.1625m3

Score 2:4

Score 2:4


• However as the reels with the doypacks are very heavy theoretically you reach the weight limit of a lorry before you reach the volume limit. Besides that reels are always stacked only one layer. So anyhow you will have plenty of space on the lorry.


• 4800 tubs/lids & labels= 10.6m3 • 4800 doypacks = 0.1625m3

Score 3:4

Score 4:4


• We have our container production in house. So transport of empty containers is no issue.


• 4800 tubs/lids & labels= IHP • 4800 doypacks = 0.1625m3

Score 4:5


• We have our container production in house. So transport of empty containers is no issue.

• But we still need 1.9m3 for lids + labels


• 4800 tubs/lids & labels= IHP • 4800 doypacks = 0.1625m3

Score 4:5

• What about transport packaging?


• Tub can take top load

• Outercase weight ~230g

• Doypack can’t take top load

• Outercase weight ~520g

Score 5:5

Score 5:5

• What about finished goods transport (palletisation)?

• Transport efficiency of tub +39%


• 10 cases/layer

• 10 layers

• TOTAL: 100 cases/pallet

• 12 cases/layer

• 6 layers

• TOTAL: 72 cases/pallet

Score 6:5

Score 6:5

• This comparison could go on and on…..



Mastering cost reduction techniques to improve profit margins

• Sustainability and cost reduction go very often hand in hand!

Questions?

[email protected]

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