A white paper written to challenge your thinking on what makes your product packaging more recyclable and less harmful to the environment.
Packaging production plays a significant role in the overall sustainability and recyclability of consumer goods. As concerns about environmental impact and resource conservation continue to grow, understanding the recyclability and sustainability of packaging materials becomes paramount. The ability to recycle packaging effectively and adopt sustainable practices throughout the production process is crucial for reducing waste, conserving resources, and minimising your environmental footprint.
This document contains my thoughts on the challenges that clients both existing and prospective face and aims to set the stage for discussing the intricacies of recyclability and sustainability in packaging production, highlighting the importance of addressing these factors to promote a more
eco-friendly and responsible approach to packaging design and manufacture whilst also delivering on a commercial level.
I aim to challenge what you may think as being environmentally friendly and sustainable and champion the idea that a ‘one size fits all approach does not work. We will start with choice of materials and progress for there as in my opinion it is only the start of the story.
So, here goes...
Material Choice
The choice of substrate is an important one if your packaging substrates are paper based. Fortunately, most paper and paperboard manufacturers offer ranges of materials produced from sustainable resources, and is normally managed by some form of chain of custody system. A Chain-of-custody system demonstrates that the supply chain is committed to sustainable sourcing. It verifies that there are processes in place to produce products that are sustainably sourced and lets your customers and end users know your products support responsible forestry. Chain of custody systems such as the FSC allow you to print a logo marque on your printed products so that your customers can trace the origin of the paperboard you are using in your packaging. Even if you do not wish to advertise your use of sustainably sourced paperboard, you will find that most suppliers worldwide adhere to strict chain-of-custody systems meaning in may cases that you will already be using sustainably manufactured paperboard.
While using sustainably sourced paperboard is a positive step for the environment, many companies are taking it a step further by utilising Carbon Balanced Paper. This initiative offsets the carbon emissions associated with the paperboard used in the manufacture of your product packaging. Carbon Balanced Paper offers a straightforward way for organisations to balance their carbon footprint by protecting the world's most ecologically significant and threatened habitats, both locally and globally. It allows you to reduce the carbon footprint of your printed packaging through conservation projects undertaken by organisations like the World Land Trust (WLT). Through WLT’s Carbon Balanced programme, carbon emissions generated by a particular product or activity are offset or ‘balanced’ by the carbon stocks saved when WLT conserves ecologically important forestry under imminent threat of clearance. These standing forests ‘lock in’ carbon that would otherwise be released – and continue to absorb carbon dioxide through their lifetime.
In my opinion, this is a consideration worth taking seriously if you are committed to reducing the
environmental impact of your printed packaging. While there may be a slight premium associated with
Carbon Balanced Paper, the benefits are worthwhile, tangible, and measurable.
Production Processes.
All the efforts put into sourcing materials from sustainable origins for your product packaging can be rendered futile if the subsequent treatment of those materials makes them unsuitable for recycling after use. Therefore, it is crucial to ensure that the methods employed in processing the materials are
more environmentally friendly. To achieve this, it is essential to insist that your suppliers adopt products, systems, and processes that have a minimal impact on the environment. Today, machinery and consumable manufacturers face significant pressure to deliver more sustainable and eco-friendly production systems, processes,
and products to packaging manufacturers. As a result, numerous innovations have emerged in the industry, and any self-respecting packaging manufacturer should be well-informed about these advancements.
By collaborating closely with your packaging manufacturer and seeking their advice, you can identify and implement sustainable practices that align with your environmental goals. By taking such proactive steps, you can ensure that your packaging not only originates from sustainable sources but also retains its recyclability, promoting a circular economy. Remember, the success of sustainable packaging goes beyond sourcing materials responsibly. It extends to every aspect of the production and post-use lifecycle. By prioritising environmentally friendly systems and processes, you can make a meaningful contribution to minimising the overall
environmental impact that your product packaging has.
UV or Conventional?
In recent years, there has been a noticeable shift in the sales of new printing machinery, with a move away from UV-equipped presses towards conventional and mixed operation presses. This trend is being driven by the growing demand from brand owners, retailers, and consumers for packaging that is easier to recycle, has a lower carbon footprint, and in some cases, provides cost savings.
So, what does this mean for you as a buyer of printed product packaging?
It is important to acknowledge that there is still a need for certain packaging projects to be printed using UV-equipped presses. These presses offer the advantage of in-line special effects and stunning embellishments, creating visually striking packaging. Additionally, UV-cured products tend to be more durable as the inks are fully cured during printing and do not rely on post-printing drying time. While UV presses consume significant amounts of electricity during production, the overall carbon footprint of the end product can still be lower compared to incorporating effects through subsequent processes or subcontractors. It is essential to consider the energy and resources required for these additional processes, as well as the transportation involved, which can increase the carbon footprint and overall cost of the packaging.
Similar considerations apply to conventional presses as well.
Opting for a conventional press with a coater and an infrared/hot air drying system offers a wide range of in-line finishes. Advances in water-based coating technologies have allowed for the production of many effects that rival those achieved with UV printing. Moreover, modern conventional presses equipped with infrared consume approximately half to two-thirds of the power used by UV presses.
There are however some limitations. UV equipt presses can achieve much higher gloss levels when gloss coating than conventional presses. Additionally, when printing on coloured or metallised paperboard, it can be challenging to print designs that require white ink to be printed before the main images. The curing time for white ink becomes an issue, affecting the final result. Therefore, caution is advised when printing conventionally in such cases.
Both UV and conventional presses have seen innovations in terms of energy efficiency. Many manufacturers now incorporate technology that recycles up to 30% of the heat generated during drying or curing, resulting in significant power savings. Compared to legacy presses without this technology, savings of around 20 kilowatt hours can be achieved.
LED UV-equipped presses are worth considering, as they offer all the benefits of UV printing without the high power consumption. Power savings can be as high as 75% compared to conventional UV curing systems, translating into significant savings of up to 60 kilowatt hours. However, it is important to note that the specialized LED-compatible inks and coatings required for LED UV printing can be three to four times the cost of conventional options, potentially offsetting the power savings. A further consideration is that the range of spot colours that can be mixed is limited with LED UV, typically requiring collaboration with ink suppliers, which may impact timelines. Furthermore, the availability of coatings for LED UV is currently limited due to low demand from the industry, making their manufacture less viable for manufacturers and printing companies.
In conclusion, the choice between UV and conventional printing depends on the specific requirements of each packaging project. Understanding the advantages and limitations of each method, along with the associated costs and sustainability implications, enables informed decision-making to achieve the desired balance between quality, sustainability, and cost-effectiveness.
Inks
The selection of printing inks plays a crucial role in determining the recyclability of packaging materials. In particular, paper and paperboard printed with UV-based inks and coatings pose significant challenges for recycling. This is due to the need for a de-inking process during recycling, which aims to remove the ink pigments from the paper. However, UV inks often leave visible traces of pigments in the recycled paper, making the de-inking process more difficult. To address this issue, several ink manufacturers, have been actively working on developing UV inks that meet satisfactory
results in ISO-approved de-inking tests. If recyclability is a priority for your packaging, it is advisable to engage in a conversation with your packaging manufacturer to assess whether their processes align with your goals.
In conventional printing, there are various ink options available for packaging manufacturers. Conventional printing inks are typically oil-based and can be categorized into mineral oil and vegetable oil-based products. In modern packaging manufacturing, the preference leans towards inks derived from vegetable oils due to their more sustainable nature. These vegetable oils are sourced from crops like maize or rape seed, and after refinement, they serve as the base for ink production. It is worth noting that the technology for de-inking and recycling paper was primarily developed around printed products that utilize conventional inks. As a result, this process has matured over time and has demonstrated proven success in the industry.
In conclusion, the choice of printing inks significantly impacts the recyclability of packaging. Collaborating with your packaging manufacturer and discussing their processes can provide valuable insights and help ensure your packaging aligns with your recyclability objectives.
Coatings
Many packaging manufacturers whether UV or conventional use various types of coatings applied in-line whilst printing to protect and enhance the printed surface of a product. I have discussed the pros and cons for UV or conventional printing earlier in this white paper but the application of a coating or multiple coatings is generally used to significantly add value to the finished product without adding subsequent finishing processes such as film lamination and offline uv varnishing which makes the
paper very difficult to recycle, increases the carbon footprint and adds significant cost to the product. In some industrial packaging manufacturing environments, it is now becoming popular for presses to be equipped with multiple printing, coating, priming and drying units as well as inline cold foil units allowing for single pass production on specialist ultra-high value print products such as packaging for high end beverages and luxury cosmetics. Most of these types of press tend to be configured as mixed operation presses (able to print conventionally and with UV Inks) allowing for ultimate flexibility in single pass production. This equipment is eye wateringly expensive with some presses costing upwards of seven million euros and more in some cases and the packaging manufacturer will always need to put this specialist type of work through the press to make it pay otherwise it will find itself un-competitive in more mainstream environments.
In some smaller packaging manufacturers similar results can be achieved with some creativity. The material will have to be put through a press multiple times to achieve the desired result and it is crucial that you engage with your printer to discuss the most cost effective and environmentally friendly way of achieving your goals and aspirations.
Film Lamination
Film lamination refers to the process of applying a thin plastic film onto the surface of paperboard, typically for enhancing its visual appeal, durability, or providing barrier. properties. While film lamination can offer several benefits to packaging, it can also have implications for the recyclability of paperboard.
The presence of a plastic film layer on paperboard makes it difficult to separate and recycle the materials effectively. Recycling facilities may not have the necessary equipment or processes to separate the film from the paperboard, leading to contamination and reduced recyclability. In many cases, paperboard with film lamination may be downcycled into lower-grade products rather than being recycled into new paperboard but this can limit the circularity and value of the material. The use of plastic film in lamination adds a non-biodegradable component to the packaging, which can have long-term environmental consequences if not properly managed. Plastic waste is a significant environmental concern, with issues such as pollution, litter, and potential harm to wildlife. Plastic film-laminated paperboard poses challenges in terms of end-of-life management. If the packaging is not properly disposed of or recycled, it can end up in landfill contributing to waste accumulation. So, what should be considered and what can you do about it?
Although this can be quite costly, consider using recyclable or biodegradable lamination films as they can help improve the recyclability and reduce the environmental impact of film-laminated paperboard. Lean on your packaging designers and manufacturers so they can prioritise designs that minimise or eliminate film lamination, focusing on materials and techniques that are more easily recyclable such as in line coatings effects.
When assessing what your requirements are, you should consult with your suppliers to weigh up all of the options and the negative implications for the recyclability and sustainability of the paperboard in your packaging. By exploring alternative materials and designing for recyclability, the impact of film lamination on the recyclability and sustainability of the paperboard used in your product packaging can pretty much be mitigated.
Constructional Design & Plastic Reduction
As the world becomes increasingly aware of the environmental consequences of plastic waste, the need to adopt sustainable practices in product packaging has become paramount. Constructional design offers a powerful tool to tackle this challenge by focusing on the removal of non-recyclable elements from your product packaging. The skills of a good constructional designer presents you with an opportunity to minimize the use of these materials while maintaining the functionality, integrity and strength of your product packaging. They will be able to identify areas where excessive material usage can be reduced and identify elements that can be removed altogether. In addition to reducing non-recyclable elements, your constructional designer should be able to enhance the overall sustainability of your product packaging by designing packaging that is easy to disassemble and separate enabling efficient recycling processes. Moreover, an efficient constructional design can assist in optimising logistical efficiency too, reducing material waste and transportation volume. By designing packaging that maximises space utilisation and minimising the use of excessive packaging materials, you can minimise your environmental footprint throughout the supply chain.
Conclusion
I wrote this document as an introductory guide to assist you navigate your way through this wide reaching, complex and sensitive subject. It is certainly not an exhaustive guide, but merely my own thoughts based on my own experiences. We are all under pressure to look at the impact of what we are doing is having on our environment as well as the financial pressures from rising energy and raw material costs whilst trying to deliver maximum returns for our customers. I think you will have guessed by now if you have read this far, that I’m basically saying that a ‘one size fits all’ approach simply doesn’t cut it when considering working with a print supplier. Depending on your needs, you may even need two or three suppliers and play to each of their strengths to deliver on your aspirations. From my own experiences advising and working with clients over the last twenty five years or so, I think that it is extremely important for you as the buyer to understand what your suppliers can offer and through dialogue work out how to deliver an end product that is firstly fit for purpose and secondly ticks all of the boxes for your sustainability and recycling goals.
If you need further help!
I have been in this business for over thirty five years now and have built a strong small business with a highly skilled team of experts who are passionate about print both in the commercial and environmental sense.
We have been and continue to be disruptive in the industry challenging convention to deliver innovative solutions time and time again for our customers.
If you’re looking for fresh thinking or a different perspective on what you’re doing, please get in touch and one of us would be pleased to have a chat to see how we can help you.
Alternatively, if you just want to chat through some points, or challenge my thinking, I will welcome it. I’m always keen to learn and adapt my way of thinking.
Thanks for reading!
Written by Managing Director,
Nick Jones
