NatureFlex™ Flexible Packaging - sustainablebizness.com · Innovia Films is a global producer of...
Transcript of NatureFlex™ Flexible Packaging - sustainablebizness.com · Innovia Films is a global producer of...
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BRIEFING NOTES - MARCH 2003
NatureFlexNatureFlex™™ Flexible PackagingFlexible Packaging
Biodegradable Biodegradable && Compostable Packaging FilmsCompostable Packaging FilmsFrom a Sustainable ResourceFrom a Sustainable Resource
Malcolm Cohn - Market Manager, Americas
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""The future depends on what we do in the presentThe future depends on what we do in the present..""
---- Mahatma GandhiMahatma Gandhi
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IntroductionIntroduction
Company Overview
Why the hoopla about biodegradability & sustainability? Key Market Drivers.
Biodegradable Test & Certification Procedures
Innovia’s Product Offering
Key Market Applications
Tomato Survey
Challenges for Bio-based Films
Contents
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Company OverviewCompany Overview
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Innovia Films is a global producer of specialty Cellophane and Polypropylene packaging films.
Turnover $440 million from four industrial sites (including a major Cellophane manufacturing facility in Kansas).
Produce 260 million pounds of flexible film annually from sites in the US, England, Belgium, and Australia.
Over 1,400 employees support our operations.
State of the art R&D center in Wigton, UK
The Americas head office is based in Atlanta, GA.
Innovia FilmsInnovia Films
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Labels17%
Packaging55%
Industrials4%
Securency5%
Overwrap19%
Sales: $440 million
Films Sales by BusinessFilms Sales by Business
Film Capacities
BOPP: 192 million lb.Cellulose: 68 million lb.
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Biodegradable Biodegradable &&/or /or Sustainable PackagingSustainable Packaging
Key DriversKey Drivers
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Average $ per Barrel
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1960's 1970's 1980's 1990's 2000 2001 2002 2003 2004 2005 2006
Dependence on Oil-Based Flexible Films
8% of Oil is Converted into Plastics
Over 50% of Packaging is Plastic
Oil has increased in price 500% since 1990’s
Finite nature of fossil-fuel based materials:For every 4 barrels we are currently consuming, we are only discovering 1 new barrel…!
2005…Middle East uncertainty, Oil supply, Gas prices, Katrina, Rita
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““17 Million new Chinese consumers of plastic 17 Million new Chinese consumers of plastic will be born this year. Are you ready?"will be born this year. Are you ready?"
---- gotoemerson.comgotoemerson.com
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Key Market DriversKey Market Drivers
Significant volatility in polymer supply chain.
Finite availability of oil.
Long term aspect of Land Fills not very appealing to citizens orregulators (Europe much further along).
Major increase in focus on ‘Sustainability’(and the USA is a major driver in this…)
Corporate Social ResponsibilityOpportunity to align packaging policies within CSR programs.
Retailers want to be able to send ‘back of store’ waste straight to compost facility, without need for separation.
Consumers want ‘biodegradable’ packagingGives Supermarkets opportunity to respond to this demand.e.g. Wal-Mart, Whole Foods, Wild Oats, Carrefour (Brazil)
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Increase in use of composting as a waste management stream.
Home (Back-yard) Composting popular in certain countries & US regions.
EU legislation to progressively remove the biodegradable elementfrom landfill and direct it to composting facilities.(Biodegradable Municipal Waste to reduce to 35% of 1995 level by2016)
Key Market DriversKey Market Drivers
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Biodegradable Test & Biodegradable Test & Certification ProceduresCertification Procedures
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What is the differenceWhat is the difference??
BIODEGRADABILITY - Capacity of a substance to be broken down by micro-organisms. [No set time scale]
COMPOSTABILITY - A managed biodegradation process, through production of a useful compost in a maximum period of 180 days. This requires conformity to an agreed norm.
COMPOSTABILITY NORMS – ASTM, EN, DIN, GreenPlaU.S. has adopted ASTM 6400 and Europe EN13432.
All NatureFlex films are certified to ASTM 6400 All NatureFlex films are certified to ASTM 6400
Biodegradability v CompostabilityBiodegradability v Compostability
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Bioplastics: DefinitionsBioplastics: Definitions
Plastics from renewable resourcesPlastics made from raw materials that are renewable. These can be annually renewable (such as corn starch) or materials like cellulose from wood. Manufacturers can use the standard ASTM D6866 to identify the percentage of material made from renewablesources.
Biodegradable/compostable plasticsPlastics that will fully, and safely, disintegrate and biodegrade when composted. Not all plastics made from 100% annually renewable raw materials may be biodegradable/compostable. It depends on the molecular structure of the material itself. Manufacturers can use standards, including ASTM D6400, to determine if a material is compostable.
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Federal Biobased Product Preferred Procurement Program Federal Biobased Product Preferred Procurement Program (FB4P)(FB4P)
Independent analysis confirms “NatureFlex contains >90% biobased content based on ASTM D6866.”
NatureFlex™ selected by the Federal Biobased Product Preferred Procurement Program (FB4P) for submission for the very exacting ‘cradle-to-grave’ BEES analysis (Building for Environmental and Economic Sustainability).
NatureFlex™ will be eligible to use the ‘USDA Certified Biobased Product’ logo.
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A BRIEF GUIDE TO ASTM 6400A BRIEF GUIDE TO ASTM 6400
The biodegradability of the material is compared to a control (pure cellulose) and must biodegrade to a minimum of 90% of the control level.
Constituents of the packaging material >1% by weight must be measured individually, and also biodegrade to a minimum of 90% of the control level.
Constituents <1% by weight are exempted, but the sum of such constituents must not compromise biodegradation.
Pilot composting & plant-growing tests are also carried out on the material.
Heavy metal tests are also required.
Composting Norm for BIODEGRADABLE PLASTICSComposting Norm for BIODEGRADABLE PLASTICS
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Home composting:Only suitable for unmodified plant-based materials &materials tested specifically
Not suitable for materials that require higher temps to achieve biodegradation
Industrial composting:Suitable for all certified compostable materials
Methods of CompostingMethods of Composting
Windrow Composting(not suitable for Oxo-degradables)
In-vessel Composting
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Home Composting & Home Composting & Ambient Aqueous BiodegradationAmbient Aqueous Biodegradation
Full biodegradation confirmed within 24 days.
Test confirms:(a) Material is suitable for Home-Composting.(b) Material will biodegrade in waste-water, sewage or marine environments.
Not suitable for Oxo-degradables& certain compostables (e.g. PLA) that require higher temps.
Home composting in your own garden
Miti Test (ISO 14851) carried out by Miti Test (ISO 14851) carried out by ‘‘Organic Waste SystemsOrganic Waste Systems’’ [OWS] [OWS] in Belgium.in Belgium.
Material used 165 gauge NE2 (‘Worst case scenario’).
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Product CertificationProduct Certification
All NatureFlex™ packaging films have been fully tested & certified to the American standard ASTM 6400 as well as the European composting norm EN13432. They can therefore carry the following logos:
CompostableKompostierbar7P0085
Dincertco, GermanyAlso UK, Netherlands & Poland
OK Compost, Belgium
BPI logo, USA
They are also certified as fully ‘home’ compostable…
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InnoviaInnovia’’s Product Offerings Product Offering
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Transition plan Other ‘NE’ types
No plans currently to transition any of the following grades:
~ NE30~ DNE~ NE30 White~ NE600 Brown
Lab scale development initiated in E971 ~ Target is a ‘barrier’ version of E969. ~ No plant/customer trials likely before Q4 2006 earliest…
NatureFlexNatureFlex™™ Sustainable Product StreamSustainable Product Stream
Back to Nature
▲ ▼
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NATUREFLEXNATUREFLEX™™ COMES FROM TREESCOMES FROM TREES……
Our raw material is renewablewood-pulp sourced from managed plantationsfrom suppliers operating sustainable forestry programmes such as FSC or similar.
We take it through a complex processto dissolve it and then regenerate it as a kind of ‘transparent paper’.
We can then coat it, slit it and produce NatureFlex™ reels, with different characteristics for a range of packaging end-uses.
After use it can be composted, completing the ‘circle of life’…
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…… AND RECYCLES BACK TO NATURE AS COMPOSTAND RECYCLES BACK TO NATURE AS COMPOST
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NatureFlexNatureFlex™™ -- Key Material CharacteristicsKey Material Characteristics
Typically >95% renewable resources
Certified compostable in all key biodegradation situations(Industrial, Home, Marine & Waste-water)
Based on GM-Free wood-pulp from managed plantations
Machine friendly (anti-static, wide heatseal range, easy opening, excellent deadfold)
High gas barrier & range of moisture barrier possibilities
Excellent grease/oil resistance
Compatible heatseal to other bioplastic materials
Certain grades are microwavable
Fully Commercial…
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Fully biodegradable coating provides ultra wide heatseal rangeFully biodegradable under industrial, ambient & aqueous conditionsTropical MVTR of 2g or 24g/100 in2.24 hoursStandard availability in 75, 90, 120, 165 gauge
Micro-injection: Pigments etc, prior to extrusion Absorption: Dyes, softeners etc, post extrusionCoating: Slip, adhesion, heatseal, barrier
Barrier sealant layer
Regenerated cellulose
Barrier sealant layer
NatureFlexNatureFlexTMTM Barrier FilmsBarrier Films
Basic Material Structure
Coating
Injection or absorption
Options for modification
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Full film sheet present
Total visible disintegration confirmed
Pilot Compostability of NatureFlex™ NE film
NatureFlexNatureFlex™™ Biodegradation & CompostabilityBiodegradation & Compostability
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% d
egra
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Natureflex NP
NatureFlex NE
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Key Market ApplicationsKey Market Applications
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Key Market ApplicationsKey Market Applications
Hygiene applications~ Diapers, Feminine hygiene, etc.
Carton-box overwrap
Confectionery
Permeable applications~ Bakery~ Meat & Cheese smoking
Fresh produce ~ Moisture perm can increase shelf
life~‘Back of store’ waste to
composting
Cereals (pouch & bag-in-box)
Saran-free packaging
Bio utensil bags
Event catering~ Practical waste disposal~ Litter issue
Convenience Foods~ Fast-food chains~ In store packaging (trays etc.)
Paper bag liners
Natural/Organic products
Nutritional/Energy bar Metallized laminate structures
Cigarette Paper
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Applications Innovation Timeline Applications Innovation Timeline 2003 2003 –– 20062006
2003 NatureFlex NE :
World’s first biodegradable and compostable heat sealable cellulose film
2003 NatureFlexNP :
Non heat sealable version of NatureFlex
2003 NatureFlexNPU :
Non heat sealable tape base film
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2005 NatureFlexD-NE:
New one-side coated NatureFlex film
2005 NatureFlexNE2 White:
White NatureFlex film2005 NatureFlexNE38 Brown:
Brown NatureFlex film2006 NatureFlexNM:
World’s first metallized biodegradable and compostable film
2006 NatureFlexNVS:
New generation coated NatureFlex
Applications Innovation Timeline 2003 Applications Innovation Timeline 2003 –– 20062006
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Wal-Mart March 2006
NatureFlexNatureFlex™™ Films Films –– The transparent paperThe transparent paper……
Key Points:Palm fiber tray supplied by EarthCycle, Canada, and overwrapped with NatureFlex 120 gauge NVS, ~ 95% renewable resources.
Both tray and overwrap film certified to the compostable standard ASTM 6400.
GMO-free, tray and film suitable for home composting.
NatureFlex is static-free & heat-sealable, designed to run on standard packaging equipment without modification.
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Success at Wild Oats ...Success at Wild Oats ...
December 2006 nationwide in-store
promotion.
Palm fiber tray supplied by EarthCycle, Canada, and overwrapped with NatureFlex 120 gauge NVS
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Extension of concept to over 500 product lines starting September 2006.
Almost half of organic Fresh Produce lines are in compostable packaging. Target to hit 80% by January 2007.
Where possible materials employed are to be home compostable.
Move to save 3,550 tonnes of conventional plastics from Sainsbury's use annually.
Compostable packaging – Press Release October 3rd 2006
New NatureFlexNew NatureFlex™™ NVS forNVS for
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Followed by .....Followed by .....
By the end of 2006 both Morrison’s and Tesco had followed Sainsbury’s lead to biodegradable
packaging.
See reverse of label for packaging composting information
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““every little helpsevery little helps””
Compostable, non GM packagingfrom a sustainable source
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TOMATO PACKAGINGTOMATO PACKAGING
Survey of packaging tomatoes undertaken in Australia
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Preserving the quality of the fruit from vine to consumer is essential to successful marketing.
Consumers buy tomatoes based on:- Appearance- Flavor- Quality
Tomato PackagingTomato Packaging
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Tomato PackagingTomato Packaging
Packaging RequirementsPackaging Requirements
Protect product through-out shelf life.Shelf life extension.Reduce moisture loss.Provide oxygen permeability – via perforation or enhanced breathability.Attain an equilibrium of oxygen and carbon dioxide transmission through the package and the product’s respiration rate.
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Innovia TestingInnovia Testing
ObjectiveObjective
Understand the effect of packaging films on tomato shelf life.
Films TestedFilms Tested
3 NatureFlex films (NVS, 535E956 & NE600).2 BOPP films (one perforated, one breathable NOT perforated). Bio plastic (PLA).
MethodMethodControl was unwrapped.All films were perforated to a P8 pattern (exception above).Packed in flow-wrapped PET trays.6-8 vine tomatoes were used in each tray.Stored at 55oF over 26 days, then extended to 36 days.Tomatoes were evaluated for changes in color, firmness and weight.
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No changeWrinkled @ 26 days
Lost tomato odor
Overripe and soft @ 26 days
OK @ 36 days
MediumControl -Unwrapped
No changeWrinkled @ 26 days
Lost tomato odor
ModerateOK @ 36 days
HighestPLA
No changeMoldLost tomato odor
Moderate25 daysLowestBOPP Breathable
No changeMoldLost tomato odor
Moderate25 daysMediumBOPP Perforated
No changeNo ChangeGoodModerateOK @ 36 days
HighNE600
No ChangeNo ChangeGoodModerateOK @ 36 days
Low535E956
No ChangeNo changeGoodModerateOK @ 36 days
Low23E946
ColorSkin Appearance
AromaRipening / Softening
MoldWeight loss
Film
Innovia Testing ResultsInnovia Testing Results
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Innovia Testing ResultsInnovia Testing Results
Closer to centre is better
00.5
11.5
2
2.53
3.54
4.55
Weight loss
Mold
Ripening / SofteningAroma
Skin Appearance
NatureFlex
BOPP Perf
BOPP Breathable
PLA
Control unwrapped
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Tomato Packaging ConclusionsTomato Packaging Conclusions
Packaged tomatoes last longer than unwrapped.
Best performer = Perforated NatureFlexTM NVS.
Anti-mist is not required on the NatureFlexTM films due to their moisture permeability.
BOPP, perforated or breathable, is possible, albeit with shelf life limitations.
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Challenges for BioChallenges for Bio--based Filmsbased Films
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Moisture Barrier of Moisture Barrier of ‘‘BiofilmsBiofilms’’120 gauge films [100ºF, 90%RH]
NVS (New Development)Semi-permeable option
NatureFlex NM achieves OPPbarrier levels
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Challenges for BioChallenges for Bio--based Filmsbased Films
Currently bio-based films are substantially higher in cost compared to oil-based films.
Unlike renewable energy, bio-based films do not receive financial support during their development and market-entry stage.
However, the gap is narrowing as the price of finite fossil-fuel based materials increases.
Surveys also indicate that Consumers will pay a little more for environmentally friendly & sustainable films.
Bottled water costs 10,000 times more than tap water, and is often more expensive, per gallon, than gasoline. (Earth Policy Institute Report)
Cost!
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Challenges for BioChallenges for Bio--based Filmsbased Films
One of the industry’s biggest hurdles for the adoption of compostable materials is the lack of curb-side collection and municipal composting facilities. Municipal composting would ‘complete the circle’ for bio-based materials.
Consumer awareness programs must be introduced to educate the consumer of the need to compost, ...
Otherwise, it will all be for naught!
Other concerns!
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PACKAGING FROM NATURE, PACKAGING FOR NATURE
It’s only ... NATURALNATURAL!
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Innovation
QualityProducts
ExceptionalService
StrategicAlignment
MarketLeadership Why
?