Appendix G Packaging Tools: Best Practices

(1)

Appendix G

Packaging Tools: Best Practices

(2)

Emergency Response Environmental Cleanup Hazardous Waste Solid Waste

Underground Storage Tanks

Contracting Factsheets

Forms

Public Notices

Statutes, Rules

& Guidance

Home > Programs > Land Quality > Packaging > Best Practices

Best Practices

Best practices feature descriptions of different methods for reducing packaging waste.

Alternatives to Boxes/Cartons:

z Reusable shipping containers (49k PDF)

z Shipping bags for non-breakable items ^{(40k PDF)}

Corrugated Boxes:

z Carton reuse (48k PDF)

z Choosing the right sized shipping carton (57k PDF)

z Choosing between ECT and bursting strength ^{(143k PDF)}

z Packaging optimization and drop tests (57k PDF)

z Redesign packaging geometry ^{(44k PDF)}

z Variable depth cartons to reduce void fill use ^{(29k PDF)}

Void Fills:

z Void fill reuse (45k PDF)

z Proper inflation of air filled cushions ^{(90k PDF)}

Palletization:

z Plastic pallets (44k PDF)

z Reusable tie-down straps for pallets (alternative to pallet wrap) (47k PDF)

Recycling Considerations:

z Recyclability ^{(42k PDF)}

z Recycled content (44k PDF)

Page 1 of 2 Oregon DEQ's Land Quality Division - Packaging: Best Practices

9/27/2005

http://www.deq.state.or.us/wmc/packaging/bp/index.htm

(3)

Be sure to also check out case studies and other resources.

Updated: July 14, 2005

DEQ Online is the official web site for the Oregon Department of Environmental Quality.

If you have questions or comments about the web site contact DEQ's webmaster.

Page 2 of 2 Oregon DEQ's Land Quality Division - Packaging: Best Practices

9/27/2005

http://www.deq.state.or.us/wmc/packaging/bp/index.htm

(4)

Land Quality Division Solid Waste Policy and Program Development Section 811 SW 6th Avenue Portland, OR 97204 Phone: (503) 229-5913 1 (800) 452-4011 Fax: (503) 229-6977 www.deq.state.or.us

Updated: 06/06/05 David Allaway 05-LQ-055

Packaging Waste Reduction Best Practices

Reusable Shipping Containers

Several well-managed companies have demonstrated financial savings and waste reduction from replacing single use shipping containers with reusable/returnable crates, mobile carts, trays, totes, racks, or tubs.

Many types of reusable shipping containers are in use today, including those made of metal, plastic, paperboard, wire, or fiberboard. Once the contents are emptied, reusable containers can be collected and stacked for return to the supplier.

Containers can be collapsible or nestable for ease in backhauling. An efficient system design is dependent on specific requirements and restrictions within a shipping process.

Benefits

Although reusable shipping containers may be initially more expensive than

corrugated containers, over time there may be a cost savings. Savings are realized through reduced purchasing costs and disposal costs, although additional costs, such as return transportation and labor, may be incurred.

COMPARISON OF SHIPPING CONTAINERS BY MATERIAL (Based on typical two-cubic foot size)

ATTRIBUTE OF

CONTAINER

CORRUGATED ONE-WAY

CORRUGATED REUSABLE

FIBERBOARD REUSABLE

PLASTIC REUSABLE

Weight 1.5 lbs 2.2 lbs 5 lbs 5.5 lbs

Durability Poor Fair Fair to Good Excellent Estimated

Initial

Procurement Cost

$0.53 $1.06 $6.05 $11.03

Estimated Life 1 trip 5 trips 50 trips 250 trips Procurement

Cost/trip (avg.) $0.53 $0.21 $0.12 $0.044

Other costs Setup Disposal

Setup Breakdown Return Re-setup

Return Return

Source: Buckhorn, Inc. "How to Select Shipping Containers", Milford, OH.

Other benefits of reusable shipping containers can include improved ergonomics (improved handles and access), improved safety (elimination of box cutting, staples, and broken pallets), and less product damage due to transport packaging failure.

(5)

Limitations of Reusable Shipping Containers

Reusable shipping containers aren’t cost-effective in every situation. Generally speaking, reusable containers work better when there are closed distribution loops, a constant flow of consistent products in large volume, limited cleaning or other processing requirements, and short transportation distances.

Case Studies

The Vancouver (Washington) facility of Panasonic Shikoku Electronics Corporation of America receives television components from an overseas supplier in durable plastic trays. The trays also eliminate the need for wooden pallets. Empty trays are nested and shipped back to the supplier in intermodal containers. Annual savings exceed $65,000.

Custom floor mats used to be shipped to Toyota Logistics Services (Portland) in recyclable corrugated boxes, on pallets. Working with its supplier, Toyota switched to a pallet-free, durable plastic tote.

Empty totes are collapsed, stacked, and backhauled to the supplier in California. Savings are estimated at $24,500/year.

For More Information

The following two sites provide additional information intended to help businesses switch to reusable transport packaging:

• Reusable Transport Packaging Directory: http://www.moea.state.mn.us/transport/index.cfm

• Reusable Transport Packaging: There’s a Better Way: www.better-way.info

Credits: Alameda County (CA) Waste Management Authority & Alameda County Source Reduction and Recycling Board; Minnesota Office of Environmental Assistance; Twin Cities Solid Waste Management Coordinating Board.

Alternative formats (such as large type, Braille) of this document can be made available. Contact DEQ’s Office of Communications & Outreach, Portland, at (503) 229-5317

(6)

Packaging Waste Reduction Best Practices

Shipping Bags for

Non-Breakable Items

For direct-to-customer shipments of non-breakable items, shipping bags may be an attractive option to consider. Many leading retailers already use bags or other flexible packaging to ship clothing, linens, and other soft goods to customers via delivery services such as the USPS, FedEx, and UPS. In certain circumstances, shipping bags or flat mailers are also used for shipping certain office supplies and paper products, books, electronic media, and even mail-order pharmaceuticals.

Financial Considerations

Bags and flexible packaging offer the potential of several financial advantages to the order fulfillment center:

• Procurement: Shipping bags typically cost less than corrugated boxes and void fill.

• Storage: Bags store more compactly, requiring less storage space.

• Labor: Bags can be easier to use, avoiding the time spent setting up, stuffing, and taping shut boxes. Norm Thompson Outfitters found that an average order packer can fill 32% more orders per hour using bags instead of boxes.

• Outbound Freight: Shipping bags usually weigh less than boxes with void fill, and thus offer the potential for savings in shipping charges.

Norm Thompson estimates that it saves more than $1.1 million and reduces packaging use by more than 600 tons annually through its use of shipping bags for fulfilling clothing orders from customers. Click here for details.

Of course, bags and other flexible packaging are not appropriate for shipping items that need additional protection, including items that are fragile, breakable, bruisable and items with sharp edges or protrusions. Using a bag to ship fragile items may increase expenses and waste, if the product is damaged and has to be replaced. In these instances, a rigid package such as a corrugated carton is likely a better choice.

Material Options

There are many different types of shipping bags and envelopes to choose from.

Variables include the following:

• Padded or unpadded. The most common types of padding are polyethylene foam, polyethylene bubble, and macerated newsprint.

• Paper, plastic, or composite (paper/plastic blend).

• Rigid or flexible. While most shipping bags are flexible, some envelopes are made from thick chipboard that is rigid and holds its shape under moderate pressure.

• One-way or two-way mailer. Some shipping mailers have a peel-off tab and adhesive strip that allow the mailer to be used for returns.

• Generic or custom-printed. Stock shipping bags are available in a limited variety of colors. Some retailers purchase custom-printed shipping bags with their corporate logo and/or colors printed on the bags.

• Level of post-consumer recycled content. Increasing post-consumer content can reduce several environmental burdens associated with manufacturing the shipping bag.

(7)

Environmental Considerations

Shipping bags typically offer several environmental advantages over corrugated cartons. Because they typically weigh so much less, fewer raw materials and energy are required in manufacturing, and

associated air and water emissions are reduced. Shipping bags’ smaller volumes and weight also reduce fuel use and associated emissions when packaged products are shipped to customers.

One study compared ten different shipping bags against two different corrugated boxes with eight different void fills each. It found that all of the shipping bags – even those made entirely from virgin materials and with limited recycling options – required less energy over their entire life cycle than any of the box/void fill options. Similar results were found for most of the atmospheric and waterborne

emissions studied. This isn’t to say that recycled content and recyclability aren’t important – they are, and the Oregon DEQ encourages recycling and use of recycled content in packaging materials.

Rather, the study found that the lower weight and volume of the shipping bags more than

compensated, in terms of raw materials use and most emissions, for the bags’ typical lack of recycled content and recyclability.

(8)

Packaging Waste Reduction Best Practices

Reusing Corrugated Cartons

If your business is like most, you’re both receiving product in packaging from suppliers, and buying new packaging to ship product to your customers. Can the packaging “waste” that comes in be used one more time, before recycling? This strategy is called reuse and a growing number of businesses are discovering its benefits. Typically, reusing a box is even better than recycling it, both for financial and environmental reasons.

Reuse In-House

The greatest financial benefits typically are found when businesses are able to reuse boxes themselves.

Some businesses are able to reuse cartons that their vendors have used to ship supplies or parts. This reduces the need (and cost) of purchasing new corrugated boxes.

If being re-used for shipping, cartons need to be free of address labels and other markings that could cause confusion during shipping. At least one company, Nike, has developed a sticker for its box reuse program. The sticker covers old address information and also informs customers that the box is being reused. There are also mask out paints available in both tan and white that can be used to cover old

markings, although these paints may be flammable and respiratory irritants. In any case, boxes should not be re-used for shipment if they are printed with labels such as

“hazardous”, “flammable”, etc.

The key to successful box re-use is to make it easy for order fulfillment center staff to choose reused boxes. Some companies put their empty, reusable boxes into bins or totes for transfer to the packing/shipping area. Order fulfillment staff are encouraged to pull from these areas first. Typically, boxes are not flattened, which then saves employees time in flattening boxes for recycling and setting up new boxes.

Some businesses distinguish between boxes reused for shipment to customers vs.

boxes reused internally. Higher quality, “cleaner” boxes are used for customer orders.

For internal or inter-company transfers, appearance and aesthetics is less important.

Other businesses have switched to packaging that is designed to be reused tens or hundreds of times, such as durable plastic totes. That kind of reusable transport packaging is profiled in a separate document (click here).

Case Studies

Read how several Oregon businesses are saving money through carton reuse:

• The Portland order fulfillment center of OfficeMax reuses corrugated cartons from vendors and a large customer.

• The factory and order fulfillment program at Rejuvenation operates a successful box reuse program, where reused boxes are used for inter-company shipments, catalog fulfillment, and shipments to retail stores. Annual savings exceed

$22,000.

Reuse by Others

Even if you can’t re-use vendor packaging yourself, someone else may be able to...

including your vendors! Click here for an example of how a Xerox facility worked with its vendors and a third-party packaging management company to implement a closed- loop reuse program for corrugated cartons.

(9)

“Reuse” and “Recycling”:

What’s the Difference?

To the casual observer, “reuse”

and “recycling” may be the same.

In fact, many people use the word

“recycling” when talking about

“reuse”. But from both a financial and an environmental standpoint,

“reuse” and “recycling” are very different.

Take corrugated cartons for example. Reuse involves using the carton again in its original form, thus avoiding the need to purchase a new carton. In contrast, recycling involves sending old cartons to a paper mill, where they are pulped and used to make new products. Both activities reduce waste and can save money, but reuse is typically preferable. Like recycling, reuse saves money on disposal fees.

But reuse also saves money as fewer new cartons have to be purchased.

Making a carton from recycled corrugated requires less energy and virgin resources compared to producing cartons entirely from wood. But reusing a carton means one less carton is produced entirely, with greater resource savings and pollution reduction benefits. That’s why both the EPA and the State of Oregon say that while recycling is good, reuse is often

environmentally preferable: reuse first, then recycle.

Materials Exchanges

Materials exchanges are on-line services that make it easy for businesses with surplus or unwanted inventory to find other

businesses (or individuals) who are looking for the very same material.

A web portal to materials exchanges serving the Pacific Northwest is Northwest Materialsmart: www.nwmaterialsmart.org.

Corrugated Cartons

Some communities also have businesses that will redistribute used corrugated cartons that are in good condition. These businesses typically sell surplus boxes, and some also operate a box buy-back program, where used boxes in good condition are purchased for a percentage of the surplus selling price.

A McGary Boxes (Tualatin): (503) 657-4600

Sells and buys reused boxes if in good condition and a standard size.

Boxes2Business (Clackamas): (888) 353-1854 Sells pallet quantities of used boxes.

Boxes Barrels & Pallets (Beaverton): (503) 520-1536

Sells and buys reused boxes if in good condition and a standard size and sufficient quantity.

Carton Service (Portland): (503) 227-6428 http://www.cartonserviceonline.com

Sells surplus boxes and also buys used boxes if in good condition and a standard size. Also sells reused expanded polystyrene foam, bubble wrap, and wadded paper.

You may find other companies under “Boxes-Used” or “Boxes- Corrugated & Fiber” in your telephone directory.

Alternative formats (such as large type, Braille) of this document can be made available. Contact DEQ’s Office of Communications &

Outreach, Portland, at (503) 229-5317

(10)

Packaging Waste Reduction Best Practices

Choosing the Right Sized Shipping Carton

The size of corrugated shipping carton you choose can be one of your most important strategies for packaging waste prevention and corresponding environmental benefits.

As shown in this study, it typically requires much more energy to produce a

corrugated box than it does to produce the void fills used to fill the box. From these results you can understand the environmental benefits of using a properly sized carton, and see why it becomes important to stock enough different cartons in your inventory so they are relatively close in size to the products you ship. You avoid shipping products in boxes that are grossly oversized, and using an excess of void fills or cushioning materials. By shipping in the smallest possible package you keep packaging material out landfills and ultimately save in both packaging and shipping costs.

What’s the difference between “void fill” and “cushioning”? Void filling is simply filling the void space created when the product you are shipping does not completely fill its shipping carton. This keeps the product from shifting and bouncing during transport, but does not necessarily cushion the product on all sides. In contrast, cushioning surrounds a product and holds it in place while absorbing shocks and vibrations during shipment. Cushioning provides a higher level of protection than void filling, but cushioning isn’t always necessary.

When shipping non fragile items where no cushioning is required, choose a carton that comes closest to matching your product’s size. Void fill any remaining space within the package, if needed. Some items may require no void filling at all (here it may be appropriate to look into a shipping bag).

If you are shipping items in stock packaging where cushioning is required, each freight carrier may have slightly differing recommendations. Adhering to these minimum packaging guidelines may have an effect if filing claims on goods damaged in shipment. That is not to say that you must follow a carrier’s recommendations, as in many cases they can be overly protective. In order to see if it is possible to vary from a freight carrier’s recommendations take a look at these suggestions. Here is a sampling of carrier cushioning recommendations…

UPS

“Each item should be surrounded by at least two inches (five cm) of cushioning and be placed at least two inches (five cm) away from the walls of the box.

This will protect your items from product-against-product damage and shield them from the shock and vibration that can be conducted from the exterior of the box to its contents in transit.”

http://www.ups.com/content/us/en/resources/prepare/guidelines/prepare_pack age2.html

FEDEX

“Use at least 2" to 3" of packing material all around the item (item should be centered). Fragile items require more cushioning.”

http://www.fedex.com/us/services/shipinfo/packaging/ground.html

(11)

USPS

“Place the cushioning all around your items. Close and shake the box to see whether you have enough cushioning. Add more newspaper, styrofoam, bubble wrap if you hear items shifting.”

http://www.usps.com/send/preparemailandpackages/preparingpackages.htm

To illustrate the benefit of having a good variety of stock cartons in your inventory let’s take a look at a couple of examples. First let’s look at a commonly used 12x12 footprint carton and see how only varying the height effects the fiber content. The following table illustrates the difference in fiber content from one carton height to the next.

Carton Height Carton Weight (lbs) % Weight Savings (By using the next smallest

size)

12” 1.011 4.15 %

11” 0.969 4.33 %

10” 0.927 4.75 %

9” 0.885 4.86 %

8” 0.842 4.99 %

7” 0.800 5.25 %

6” 0.758 5.54 %

5” 0.716 6.00 %

4” 0.673 6.24 %

3” 0.631 6.66 %

2” 0.589 -

Table 1: 12”x12” Carton Weight Differences

You can see that every inch you can eliminate will have an impact. The percentage savings gradually decreases as you increase in height due to the fact that the 12” x 12” footprint does not change and the flap area remains constant. Even though the savings might seem small, over hundreds or thousands of shipments these savings will add up.

One suggestion here is to avoid cartons where the length and width are much larger than the depth.

These cartons will have excessively large flap areas in comparison to the body of the carton. If this configuration is necessary, consider using either a telescoping box (Figure 1) or an end loading carton (Figure 2) which will have a much smaller flap area and total fiber content.

Figure 1:

Full Telescoping Design Style Tray

Figure 2:

End Loading Carton

(12)

Now let’s take a look at a second example using cubic cartons and varying all dimensions at the same time.

Carton Size Carton Weight (lbs) % Weight Savings (By using the next smallest

size)

12” x 12” x 12” 1.011 15.63 %

11” x 11” x 11” 0.853 17.12 %

10” x 10” x 10” 0.707 18.53 %

9” x 9” x 9” 0.576 20.66 %

8” x 8” x 8” 0.457 22.76 %

7” x 7” x 7” 0.353 25.78 %

6” x 6” x 6” 0.262 -

Table 2: Cubic Cartons

Here you can see how every inch you can take out of your carton will have a large impact on the amount of fiber used.

An added benefit of reducing the size of shipping cartons is material saving for internal cushioning or void fills. Less empty space translates into less void fill use. Click here for an example.

Finally, smaller cartons ship more compactly, so keeping carton sizes close to the size of the products being shipped allows more cartons per truck. This improves transportation efficiency and reduces truck traffic, fuel use, and associated air pollution.

Thus, having a reasonable variety of different stock cartons is an important environmental strategy, allowing for reductions in environmental impacts of corrugated fiber, void fill/dunnage, and

transportation.

Example

Stocking a greater variety of box sizes can slightly complicate inventory management, and unit prices of boxes might be higher for smaller orders. However, the savings in void fills may compensate for that change. Here’s an example using real material prices at a hypothetical business, one that uses 40,000 11” x 11” x 11” cartons per year. In this example, 25% of the cartons (as shipped) have an extra 2” of empty head space (they are only 9” full). The head space is filled using layers of ½” polyethylene bubble.

Replacing 10,000 of the cartons with cartons that are only 9” high would increase unit prices for cartons, but would eliminate the need for extra bubble, at a net savings of $1,300/year, not including savings in reduced warehouse space and loading cycle time needed for the bubble wrap.

(13)

Before After 11 x 11 x 11” boxes

40,000 @ $0.2940 each $11,760

30,000 @ $0.3106 each $9,318

11 x 11 x 9” boxes

10,000 @ $0.3140 each $3,140

½” bubble layered to fill

top 2” gap in 10,000 boxes $2,000 $0

Totals $13,760 $12,458

Savings $1,302

Thus, even if optimization and diversifying box inventory leads to slightly higher unit prices, it can still yield financial benefits.

(14)

Packaging Waste Reduction Best Practices

Bursting Strength vs.

Edge Crush Test

Choosing the right corrugated carton can be a relatively simple task. Size up the item you wish to ship, select an appropriate carton, load your item, surround it with

cushioning material or dunnage if needed, and ship it on its way. But when you go back and stop to look at the number of different types of corrugated you have to choose from, things become a little more confusing. There are varying thicknesses (single wall, double wall, triple wall, etc.), several different flute types (A, B, C, E, F, etc.), and a wide variety of papers that can be used in corrugated construction. All of these factors determine the strength and durability of the carton. Too weak, and the carton may collapse or puncture. But too strong, and you’re paying for material you don’t need.

When choosing the proper corrugated carton from an environmental standpoint selecting a properly sized carton can make a very big difference. Using post-

consumer recycled content is another important consideration. But even cartons with high levels of post consumer content require energy and create pollution in their manufacture, so reducing the total amount of material used is an important

consideration. Besides reducing carton size, another waste prevention strategy is to avoid purchasing cartons that are overly protective.

There are currently two tests used throughout the corrugated industry to determine strength. Historically, the long time industry standard has been the Bursting (Mullen) Test, which is related to the rough handling durability of corrugated material. Bursting Test is a measure of the force required to rupture or puncture the face of corrugated board and is measured by a Mullen Tester. This force is indirectly related to a

carton’s ability to withstand external or internal forces and thus to contain and protect a product during shipment. Bursting strength is reported in pounds (for example, 275#).

A newer standard that has achieved widespread acceptance is the Edge Crush Test (ECT). This is a true performance test and is directly related to the stacking strength of a carton. ECT is a measure of the edgewise compressive strength of corrugated board. It is measured by compressing a small segment of board on edge between two rigid platens or plates perpendicular to the direction of the flutes until a peak load is established. This is measured in pounds per lineal inch of load bearing edge (lb/in), but usually reported as an ECT value (for example, 44 ECT).

(15)

Mullen Tester Edge Crush Tester

Corrugated Board Strength Equivalencies:

Single Wall Corrugated

Bursting Test Minimum Edge Crush Test Maximum Suggested Loading Limit Per Carton

125# 23 ECT 20 lbs.

150# 26 ECT 35 lbs.

175# 29 ECT 50 lbs.

200# 32 ECT 65 lbs.

275# 44 ECT 95 lbs.

350# 55 ECT 120 lbs.

Corrugated Board Strength Equivalencies:

Double Wall Corrugated

Bursting Test Minimum Edge Crush Test Maximum Suggested Loading Limit Per Carton

200# 42 ECT 80 lbs.

275# 48 ECT 100 lbs.

350# 51 ECT 120 lbs.

400# 61 ECT 140 lbs.

500# 71 ECT 160 lbs.

600# 82 ECT 180 lbs.

Here it is important to point out that the equivalent ECT values are give as a minimum value. This is because corrugators may use one of many different “recipes” to make each type of corrugated. Each makeup will vary slightly in overall strength. For example differing formulas for a 200# single wall corrugated will cause the equivalent ECT board to vary between 32 ECT and 44 ECT. It is important to understand what type of corrugated you are using before deciding to substitute any equivalent.

For example, if you are shipping a product that weights between 50-65 pounds, a 32 ECT single-wall carton should be sufficient, in most cases. If your carton is going to be subjected to severe handling, the 200# carton might be a better option. It would be equivalent to a carton with an ECT of 32 or higher, and the bursting test is more of a true measure of rough handling.

(16)

The fundamental difference between the two tests is that under the Burst Test a minimum board basis weight is required. That is, the Burst Test requires that the base papers used to make corrugated fiberboard weigh at least a certain minimum number of pounds per given unit area. The ECT eliminated this requirement, which allows the use of lighter weight materials while still providing high performance.

When you are comparing two identically sized cartons with equivalent strengths, one being Burst Test rated and one being ECT rated, the ECT rated carton will weigh less. In other words the ECT rated carton will use less corrugated material.

For example compare a 275# single wall to an equivalent 44 ECT single wall corrugated board. On average, the 275# Burst Test rated single wall carton will weigh 175 pounds per 1000 square feet of material used. An equivalent 44 ECT rated single wall carton will weigh on average 149 pounds per 1000 square feet of material used. The 44 ECT board will reduce the material used by 14.8%.

Put differently, the proper ECT rated corrugated provides an equivalent level of strength, but uses less material. This translates into fewer raw materials, lower energy requirements, and reduced pollution, in all stages of the package’s life cycle. Combining lighter materials in a properly sized carton with

increasing amounts of recycled content means ECT rated corrugated reduces waste even further.

(17)

Packaging Waste Reduction Best Practices

Packaging Optimization and Drop Tests

Packaging optimization is a waste prevention technique that eliminates unnecessary packaging by balancing the use of packaging materials with the protection each will provide. Simply put, an optimized package allows a product to be safely passed through the shipping environment while using the least amount of packaging material.

The level of safety during shipment can be as simple as requiring that a product arrives showing no signs of damage, or it can require that the product and package meet a set of predefined national or international testing standards. In either case the benefits of optimization include reducing waste, using the smallest possible shipping package, and an overall savings in both materials and shipping costs.

For most users of stock packaging a level of optimization can be achieved by gaining an understanding of the product, shipping environment, and available packaging materials. Start by asking yourself the following…

• What is the product value?

• What are the physical characteristics (length, width, height, weight)?

• How fragile is the product?

• Is there an acceptable level of damage?

• What are the modes of transportation (air, truck, rail, boat, etc)?

• Is the package to be reused?

• What is the packaging budget?

• What packaging materials are available?

• What are the packaging properties and what is the best application for each?

Once you gain a basic understanding of the product and how it will be shipped, optimization can begin. Does the existing (or proposed) shipping package just meet your requirements, or does it provide a higher level of protection than required? Do you really need to use a double wall carton, or will a single wall carton get the job done? Does you product even need a carton or will a simple shipping bag work? Is any cushioning actually required? If yes, will half the amount still protect your

product? This is a basic group of questions that gets you thinking about optimization.

A simple way to test is to make a change to your shipping package and do a real life shipping test. Ship your product to a location where it can be returned. Once it comes back evaluate the product and package. Is the product damaged? Keep refining your package until you are using just the packaging material that is required.

If the goal is to have your shipping package comply with one or more of the national or international standards, then professional help will be required. Package testing can be used to help to ensure that your product can be safely passed through the shipping environment. It provides real life data that will help you determine if your shipping package is performing as intended. If not, it gives packaging engineers insight as to where problems lie, and aids in determining a solution. The American Society for Testing and Materials (ASTM) and International Safe Transit Association (ISTA) have developed a wide variety of testing standards with the goal of evaluating transport packaging. A testing lab will have the capability of running your packaged product through any number of these testing standards and provide real life shock/vibration data. ISTA has programs for both certificated testing laboratories as well as certified

(18)

packaging laboratory professionals. ASTM has a listing of testing laboratories but states that they have not attempted to investigate, rate, endorse, approve or certify any laboratory. More information can be found at the following links.

ASTM:

http://www.astm.com/cgibin/SoftCart.exe/LABS/index.html?L+mystore+ewbo7432+1115670780 ISTA:

http://www.ista.org/Certification/CertificationHome.htm

Common package tests include drop and vibration testing in any number of configurations. In either case, an accelerometer which measures the deceleration of gravity in units called “G’s” is attached to the product and placed within the package being tested. In a drop test the package is simply dropped from a predetermined height and the resulting G level is measured. A vibration test subjects the packaged product through any number of vibration profiles by use of a vibration table and the resulting G levels are recorded. Packaging engineers who can determine the best course for optimization can then analyze this data and propose necessary changes.

Swing Arm Drop Tester Vibration Table

For an example of how one Oregon business used optimization to reduce interior cushioning by 40%, click here.

(19)

Packaging Waste Reduction Best Practices

Redesign Box Geometry

Changing the dimensions of a corrugated box can reduce fiber content and packaging waste. Recall that the volume of a box equals its height multiplied by width and length. By changing these three dimensions, you may be able to maintain the same volume but reduce the amount of fiber used.

The most common types of corrugated shipping cartons are Regular Slotted Cartons (RSCs). RSCs have top and bottom flaps that fold and meet in the center, thus helping to prevent bursting by evenly distributing the weight over the flap surfaces.

Generally speaking, with RSCs, the most efficient shape (least fiber per unit of volume) is a carton where the length and height (also referred to as “depth”) are the same (or very similar), and the width is about half of the length. Very shallow RSCs, where the height is less than either length or width, have excessively large flap areas in comparison to the body of the carton.

You can evaluate different box geometries for RSCs using the following formula. The goal is to maximize the ratio of box volume to “flat area”. Flat area is illustrated in Figure 1. This provides you with the most volume for the least amount of fiber.

Step one: Calculate box volume

Box volume = H x L x W

Where H = box height; L = box length; and W = box width

Step two: Calculate flat area

Flat area = (H + W + 0.5 inches) x (2W + 2L + 1.875 inches)

(Note: This formula is for a B-flute single wall corrugated RSC, but is a reasonable approximation for other common flute types.)

Step three: Divide box volume by flat area (volume/flat area).

Repeat these three steps for an alternative box geometry (ideally, one with the same volume). The box with the highest result (box volume divided by flat area) provides more shipping volume per material used.

(20)

Figure 1.

Regular Slotted Carton – Flat Area

If very shallow cartons are necessary, consider using either an end loading carton (which will have a much smaller flap area and total fiber content), a telescoping design style tray, or a die cut carton (also referred to as “corrugated mailers”). All things being equal, an end-loading carton will contain less corrugated than a telescoping design style tray with the same dimensions.

Figure 2:

Full Telescoping Design Style Tray

Figure 3:

End Loading Carton

(21)

An Example

An Oregon manufacturer of bean dips and salsas packages product in 16-ounce polypropylene tubs.

The tubs are frequently shipped 12 per carton. The conventional layout is “6 down, 2 up” (2 layers of 6 tubs each; see Figure 4). The resulting carton is very shallow and requires a total of 745 square inches of corrugated.

An alternative layout (Figure 5) is “4 down, 3 up”. In this approach, the carton holds 3 layers of 4 tubs each. The carton only requires 704 square inches of corrugated. It holds the same number of tubs but with a 5.6% reduction of fiber when compared to the conventional design. As an added advantage, the filled cartons ship more compactly on standard pallets, allowing 7.7% more product on a typical 40 x 48” pallet.

Figure 4.

Conventional Design

Figure 5.

Improved Design

(22)

Packaging Waste Reduction Best Practices

Using Variable Depth

Cartons to Reduce Void Fill Use

Variable depth cartons can be used to reduce the need for void fill when shipping.

Avoiding excess void fill is not only better for the environment, but also for your bottom line. A smaller shipping package reduces both void fill and overall transportation impacts.

The variable depth carton has multiple scores in the depth direction. You simply cut each side down to the desired depth with a standard box cutting knife and fold in the resulting flap. The final carton has clean corners for a professional appearance and more closely conforms to the product in depth.

Typical Variable Depth Carton

After Cutting:

Smallest Depth Configuration Before Cutting:

Largest Depth Configuration

While variable depth cartons reduce void fill and allow more cartons to be packed in a truck, they don’t reduce the quantity of corrugated fiber used. As shown in the

DEQ/Franklin study, energy used to produce corrugated boxes is often significantly higher than energy used to produce void fills. From the perspective of waste

prevention, the best option is to stock a variety of different sizes of boxes. Having the

“best sized” box reduces corrugated use and void fill use. Once the inventory of boxes has been optimized, adding a variable depth feature allows for even further reductions in void fill use.

Alternative formats (such as large type, Braille) of this document can be made available. Contact DEQ’s Office of Communications & Outreach, Portland, at (503) 229-5317

(23)

Packaging Waste Reduction Best Practices

Reusing Void Fill Packaging

If your business is like most, you’re both receiving product in packaging from suppliers, and buying new packaging to ship product to your customers. Can the packaging “waste” that comes in be used again, before recycling? This strategy is called reuse. A growing number of businesses are

discovering its benefits. The greatest savings often occur when a business reuses inbound packaging for outbound shipments. The next best option is to make your “waste”

packaging available to another business for their use.

Recycling is the next best option after that.

Reuse In-House

The greatest financial benefits typically occur when businesses are able to reuse packaging themselves.

Some of the easiest void fills to reuse are the flowable loosefills. These include polystyrene and corn starch

“peanuts”. When inbound cartons are unpacked, loosefills can be dumped into polyethylene bags, drums, or gaylords.

Reused loosefills require the same amount of storage space as loosefills purchased new.

Some companies find a “peanut vacuum” useful for removing loosefill from cartons and consolidating it with minimal effort.

These vacuum peanuts from cartons and consolidate them in a larger container, such as a bulk bin or large poly bag.

Bubble wrap and foam pads are other materials that are relatively easy to separate, consolidate, and reuse without requiring more storage space. In contrast, wadded paper, while reusable, takes up more space than unwadded sheets of purchased paper.

Some businesses shred their waste paper (either office paper or old corrugated boxes) to be used as a void fill.

Case Study

Set ‘N Me Free, a Gresham manufacturer of aloe vera

products, reuses all incoming void fills, including bubble wrap, expanded polystyrene, and wadded paper, and also makes its

own shredded void fill from office paper, saving over $5,000 annually.

“Reuse” and “Recycling”:

What’s the Difference?

Many people confuse the words

“recycling” and “reuse”. But from both a financial and an environmental standpoint, “reuse” and “recycling” are very different.

Take expanded polystyrene loose fill for example. Reuse involves using the loose fill again in its original form.

Reuse avoids the need to purchase (and produce) new loosefill. In contrast, recycling involves sending the loosefill to a recycler, where it is ground into tiny pieces and used to make new polystyrene products. Both reduce garbage costs, but reuse saves more money because less new loosefill has to be purchased.

Making loosefill from recycled polystyrene requires less energy and virgin resources than polystyrene made entirely from fossil fuels. But reusing loose fill means less polystyrene is produced entirely.

Reuse has greater resource savings and pollution reduction. That’s why both the EPA and the State of Oregon say that while recycling is good, reuse is often environmentally preferable:

reuse first, and then recycle.

Reuse by Others

If you can’t re-use vendor packaging yourself, someone else may be able to.

Materials Exchanges

Materials exchanges are on-line services that make it easy for businesses with surplus or unwanted inventory to find other businesses (or individuals) that are looking for the very same material. A web portal to materials exchanges serving the Pacific Northwest is Northwest Materialsmart: www.nwmaterialsmart.org.

(24)

Polystyrene Loosefill

Many mailing companies will accept bulk bags of expanded polystyrene loosefill “peanuts” for re-use.

The Loosefill Packaging Council’s “Peanut Hotline” (800-828-2214 and

http://www.loosefillpackaging.com/search/default.asp) identifies locations that accept loosefill for reuse.

(25)

Packaging Waste Reduction Best Practices

Proper Inflation of Air-Filled Cushions

Air filled cushions are a dunnage option that provide cushioning and efficient void fill. They can also reduce the amount of packaging material needed to ship a product. Also referred to as “pillow packs,” air filled cushions start out as either a low density or high density polyethylene (PE) film tube on a roll. The film is then inflated, heat sealed, and finally

perforated creating a string of pillow packs that can be torn off and used as needed. Varying levels of automation allow pillow packs to be used in low to high volume packaging operations. Standard roll widths are 8” and the lengths of each pillow pack can be set depending on the application.

Most of the higher volume equipment can be adjusted, allowing for the fill volume of the pillow packs to be varied. When it comes to reducing packaging waste this becomes important. If pillow packs are used just for void fill and not cushioning, making sure that the pillow packs are fully inflated can reduce packaging cost and waste.

Typical Automated Pillow Pack

What’s the difference between “void fill” and “cushioning”? Void filling is simply filling the void space created when the product you are shipping does not

completely fill its shipping carton. This keeps the product from shifting and bouncing during transport, but does not necessarily cushion the product on all sides. In contrast, cushioning surrounds a product and holds it in place while absorbing shocks and vibrations during shipment. Cushioning provides a higher level of protection than void filling, but cushioning isn’t always necessary.

If your goal when using pillow packs is to void fill and also cushion the product, then you will want a pillow pack that is not completely filled. This will allow the

pillow packs to be molded to the shape of the product while still being flexible enough to absorb some shock and vibration during shipment.

Updated: 06/06/05 David Allaway 05-LQ-049 Typical Pillow Pack Void

On the other hand, if void fill is the only requirement and cushioning isn’t needed, then you can fully inflate the pillow packs. Filling the entire volume will reduce the total number of pillow packs required to void fill your package, saving in both packaging time and the amount of material being used.

Take for example two 8”x 4” pillow packs filled at the two extremes of use. The first pack is filled to where it becomes approximately ¾” thick for the application where void fill and some cushioning are required. The total volume in the first case is 19.88 cubic inches per pack. In contrast, consider the second pack which is completely filled, to the point where it still has some give but will not pop when pressed. This would be for the application where only void fill is required (no cushioning). It has a total volume of 29.82 cubic inches per pack. When filled all the way the pillow packs have 33% more volume compared to the lesser filled packs. This translates into potentially a one-third reduction in the amount of dunnage used when pillow packs are inflated to match your void fill application.

Alternative formats (such as large type, Braille) of this document can be made available.

Contact DEQ’s Office of Communications & Outreach, Portland, at (503) 229-5317

(26)

Packaging Waste Reduction Best Practices

Plastic Pallets

In recent years, many manufacturers with closed-loop distribution systems have converted from wooden to reusable plastic pallets in response to financial and

technological influences. Closed-loop distribution systems are favorable for reusable plastic pallets since trucks that drop off supplies on a frequent and regular basis return to the facility where pallet loads are assembled. However, companies with non-closed loop distribution systems may benefit from the use of plastic pallets as well.

Plastic pallets are often made of recycled content plastic and molded of tough,

reinforced nylon that allows them to sustain a static load of 30,000-40,000 lbs. These pallets are compatible with most equipment such as standard forklifts/lift trucks, standard pallet jacks/racks, and automatic palletizers. Most plastic pallet producers offer a 5-year warranty on plastic pallets, and one study shows that they last for more than 300 trips.

Some of the problems once associated with the use of plastic pallets have been overcome. Many companies do not use plastic pallets for shipment outside the plant because they are more costly than wooden pallets and are not always returned to the owner. They are also hard to retain and control within the internal system. To

address this issue, some companies use bar-coding systems to track the location of the pallets. Since leasing bar-code tracking systems can cost $150-$200 per month, companies that need to track hundreds or thousands of pallets would find these systems cost effective.

For smaller companies, the use of a deposit system creates an incentive for

transporters to return plastic pallets to the company that purchased them. It is also possible to imprint the company’s name on the plastic pallets. These are just a few of the innovative ways in which companies are ensuring that they retain the plastic pallets that they purchase.

Another concern with plastic pallets is that they can have slick surfaces. In response to this problem, plastic pallet producers are instituting changes to plastic pallet production. Some manufacturers add sand in the plastic mix when producing the pallets while others add a non-skid strip to the surfaces. Both of these practices reduce product slippage and damage.

Benefits

The advantages of plastic pallets over wooden can include:

• Labor savings—eliminates need for pallet repair

• Recycle/ reuse capability

• Extended life

• Lower disposal costs

• Avoids insect-related restrictions and treatments required of solid wood packaging materials (relevant only in import and certain export applications).

(27)

TABLE 1: PERFORMANCE COMPARISON OF AVERAGE WOODEN VS. PLASTIC PALLETS

DESCRIPTION WOODEN PALLETS PLASTIC PALLETS

Initial cost $5–12 $35-60

Weight 60 lbs. 50 lbs.

Estimated life 5 trips Hundreds of trips

Repair costs $6/month/per pallet $0 - No repair costs

Strength Same Same

End-use Recyclable for parts; energy recovery

(hog fuel); compost or mulch Limited recycling opportunities Storage Some deterioration No apparent effect when stored outside

While a plastic pallet may cost four to twelve times more than a wooden pallet, companies with closed- loop distribution systems may save money because plastic pallets last longer. Furthermore, the company will save money due to less frequent repair needs, and may save money on waste management costs, since, over time, less waste will be generated.

For a case study of plastic pallet use, click here.

Credits: Alameda County (CA) Waste Management Authority & Alameda County Source Reduction and Recycling Board.

Alternative formats (such as large type, Braille) of this document can be made available. Contact DEQ’s Office of Communications & Outreach, Portland, at (503) 229-5317

(28)

Reusable Tie-Down Straps/

Bands for Pallets

Overview

Stretch wrap and disposable metal or plastic bands are commonly used to contain and secure palletized items during movement and storage operations. Reusable tie- down straps and reusable bands are an economical alternative to stretch film or disposable strapping. They are quickly and easily applied by hand, eliminating the need for expensive application equipment. Their reusability makes t

alternative to disposing of film and metal/plastic strapping.

hem an attractive

One type of tie-down strap is rated by its manufacturer as having 2,500

Once the tie-down straps or bands are removed from the pallets they

n to pound breaking strength. It has high abrasion resistance and an over-

center buckle that locks in tension. For pallet band applications, a stretch factor of about one and a half times the relaxed length is recommended. A variety of widths of standard circumferences are available. For rough handling situations, the use of several rows of straps or bands can provide added stability.

Packaging Waste Reduction Best Practices

may be refolded and collected in strategic locations throughout the plant for workers to reapply as needed. Pallet tie-down straps can be reused hundreds of times. O average, a worker with just a little experience with pallet tie-downs should be able apply two tie-downs to any load in under a minute. Similarly, a worker with minimum experience should be able to remove two tie-downs from any load in less than half a minute.

Benefits

The following table compares cost, reusability, and equipment needed for three different options to secure pallet loads.

DESCRIPTION METAL/PLASTIC BANDING

STRETCH WRAP

TIE-DOWN STRAPS/

RUBBER BANDS

Cost $0.30-0.70/pallet $0.50-1.00/pallet Approx. $2.00 Number of

uses Once Once Hundreds

Application Need special tool From a roll By hand Removal Need wire cutter or

knife to remove With utility knife Loosen by hand Comments Can loosen, crack or

split

Creates a large volume of waste

Can retighten if necessary

The initial cost of a pallet strap will be recovered in the first 2 to 7 uses in material cost savings alone. The company should realize additional savings from reduced labor and waste disposal costs.

(29)

Benefits

For a case study of reusable pallet band use, click here.

Credits: Alameda County (CA) Waste Management Authority & Alameda County Source Reduction and Recycling Board.

(30)

Packaging Waste Reduction Best Practices

Recyclability

Many customers prefer to receive packaging that is easier to recycle, so packaging designers and engineers often consider recyclability to be an important factor in packaging selection. Conversely, packages that are difficult to recycle are viewed less favorably. Given the choice between recycling waste packaging and disposing of it in a landfill, recycling is typically the environmentally preferable choice. Recycling, in most cases, conserves energy, reduces a host of air and water pollutants (including greenhouse gases), and can reduce virgin material use and associated habitat

impacts.

When designing a packaging for recyclability, there are some important factors to consider:

Single material vs. multi-material. Packaging made from a single material is

typically much easier to recycle than packaging made from multiple materials (such as plastic laminated paperboard). If multiple materials are used, they should (ideally) be easily separated by the end-user in order to facilitate recycling, or should be designed so that they separate in the recycling process (in the pulper, etc.) without negatively impacting manufacturing operations.

“Technically recyclable” is not the same as “practically recyclable”. Just because a packaging material features the recycling logo, or the manufacturer claims that it is recyclable, does not guarantee that it will be easy or even feasible for your customers to recycle it.

Many packaging materials are “technically recyclable”, that is, processes and technologies exist to recycle them. However, fewer materials are practically recyclable. To be practically recyclable:

• recycling opportunities have to be convenient for waste generators,

• the recycling process must produce materials for which a commercially viable end-use market exists, and

• the entire process has to be economically self-sustaining (or financially supported by industry and/or government).

So for example, polyurethane foam is technically recyclable. But many consumers will have a difficult time finding someplace to accept it. In contrast, corrugated cardboard is recycled in large quantities in many communities.

Not all areas of the U.S. are the same. Just because a material is readily recyclable in your region of the U.S. doesn’t guarantee that it is practically recyclable throughout the country. If you are shipping to multiple regions of the U.S. and/or export markets, you may wish to research recycling opportunities in your key markets.

Business and household recycling opportunities may differ. Businesses, who generate larger quantities of packaging waste and may be able to take advantage of back-haul opportunities, typically find it easier to recycle than households.

Households in many rural areas as well as some larger cities may not have curbside collection, and most curbside programs accept only a limited range of material types.

Labeling can support recycling – but be careful to avoid misleading claims.

Labeling your packaging with information can support recycling. For example, you might want to note a resin ID code, or a toll-free number encouraging customers to

(31)

call to identify recycling opportunities. However, be aware that the Federal Trade Commission will enforce against environmental marketing claims that are deceptive.

Balance recyclability with other environmental considerations. While the recyclability of a

package is an important environmental consideration, thought should be given to other criteria as well.

In fact, recycling is a lower priority for many businesses and governments than waste prevention (using less packaging). Sometimes, using a non-recyclable material may have environmental advantages over an easy-to-recycle material, particularly if the non-recyclable material weighs considerably less.

Click here for an example. Other options to consider include reusable transport packaging and using recycled content.

Other ways manufacturers and producers can support recycling:

Besides choosing materials that are easy to recycle, and educating consumers about recycling opportunities, other ways that producers can support recycling include the following:

• Accept returned packaging wastes from customers, or make arrangements for someone else to.

• Link your customers with the recycler of your internal scrap.

• Support recycling markets by using post-consumer recycled content in your own packaging.

Increasingly, the manufacturers and designers of packaging (and products) are being asked to share in the responsibility for reducing environmental impacts over the life of their packaging. This concept is also referred to as Product Stewardship or Extended Producer Responsibility. Businesses shipping to foreign markets should also be aware of the many environmental packaging laws abroad.

(32)

Packaging Waste Reduction Best Practices

Recycled Content

Recycled content is readily available in many packaging materials, including corrugated cartons, paperboard, molded pulp, newsprint and kraft paper void fills, aluminum, steel, glass and some plastics. In fact, it is standard practice for many of these materials to include some level of recycled content. Regardless, varying levels of recycled content are commonplace, so you may be able to increase the amount of recycled content in your packaging. The following are some issues to consider when evaluating recycled content as a packaging option:

Post-consumer vs. total recycled content. “Recycled content” can mean different things to different people.

• The term “post-consumer” refers to end products that have been used by the consumer and then separated from wastes for the purpose of recycling. Post- consumer materials include materials recycled both by both households as well as non-residential end-users such as offices, grocery stores, and restaurants.

Examples include plastic bottles, block polystyrene foam, glass and aluminum containers, old newspapers, and old corrugated cartons.

• Distinct from post-consumer content is “pre-consumer” content, which includes waste left over from converting and printing processes, prior to use by an end- consumer.

When reporting recycled content, some manufacturers report total recycled content (combining pre- and post-consumer) while others report post-consumer only. Both pre-consumer and post-consumer recycled materials provide the environmental benefits of displacing virgin feedstocks (see below). Using post-consumer content has the added benefit of providing markets for materials separated for recycling by consumers.

Performance and cost considerations. Recycled packaging may perform differently in high-speed applications (such as printing and filling of consumer products) and so some equipment adjustments may be required. Performance

differences vary by material but the fact that recycled content is used today by leading companies in all industry sectors indicates that performance challenges can be

overcome.

Similarly, cost differentials vary by material and also are a function of virgin

commodity prices as well as energy prices. The relationship is usually such that as virgin commodity or energy prices rise, recycled feedstocks are increasingly favored.

Again, the widespread use of recycled content in packaging today indicates that financial barriers, when present, can be overcome.

Adding recycled content to paper- and plastic- packaging may necessitate an

increase in packaging weight. For example, recycled paper fibers are usually shorter and therefore weaker than virgin fibers. However, many of the environmental

burdens associated with increased weight (if small) are often made up for by the environmental benefits of using recycled feedstock.

Unfortunately, a few packaging suppliers create or perpetuate myths in order to discourage customers from increasing the use of recycled content in packaging. For example, a carton supplier told one company, with an order fulfillment center in the U.S. Southeast, that they “shouldn’t use post-consumer content in their carton, because it would decrease the structural integrity of cartons exposed to humidity.”