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Seventh Generation Improves the Recyclability of its Cartons
Click the link below to read the article in Packaging Digest Magazine:
http://www.packagingdigest.com/sustainable-packaging/seventh-generation-improves-the-recyclability-of-its-cartons-2017-01-12 By replacing its poly-coated carton for fabric softener sheets with an economical recyclable/repulpable alternative, Seventh Generation qualifies for the “Widely Recycled” claim on its How2Recycle label and gets a step closer to its 2020 zero-waste goal. Yet this new carton—which marks its national debut in the first quarter of 2017 for the company’s 80-count fabric softener sheets in two fragrances: Free & Clear and Blue Eucalyptus & Lavender—offers better barrier properties. How is this possible? The eight-month-long project began in March 2016 and the updated production specification was officially released in November. The packaging change did not require a switch in carton suppliers (Seventh Generation sources this carton from two companies but prefers not to identify them)—but it did require a change in paperboard for the cartons. The new board stock is HiQ Eco(B) from Hansol Paper, the largest paper mill in Korea, and contains at least 60% post-consumer recycled (PCR) content and sometimes as much as 88%. HiQ Eco(B) paperboard uses EarthCoating from Smart Planet Technologies as the liner. Hansol Paper began licensing the EarthCoating technology at the end of 2015. EarthCoating is created by blending low-cost calcium carbonate into polyolefin resin, which displaces between 40% and 60% of the plastic. According to Smart Planet Technologies, EarthCoating is engineered for efficient processing in paper recycling systems. It fractures into small, dense particles in the pulping process, thereby avoiding the challenges found with traditional plastic coatings on paperboard. EarthCoating is repulpable and recyclable because of the blending in of the minerals, and it behaves differently in the pulper. That’s why the package qualifies for the “Widely Recycled” label. The reduction of plastic is a bonus attribute, but highly appealing as well. Kelly Murosky, Seventh Generation packaging engineer, says, “That is important to us as we look to remove all virgin petroleum-based plastics from our packaging materials by 2020. Many of our bottles are already 100% PCR.” The EarthCoating mineralized poly compound is extrusion coated onto the paperboard at high speeds. This alternative barrier coating is waterproof and grease-proof, as well as heat sealable. Although not needed in this case, EarthCoating is also compliant with the Food and Drug Administration (FDA) for food contact applications. For the Seventh Generation dryer sheets project, the base paper is 400 grams per meter squared and the EarthCoating is 20 g/m2, applied on the inside of the carton. (EarthCoating can also be applied to a package exterior, providing barrier properties and a premium print surface.) By making this change in packaging materials, Seventh Generation is able to upgrade its cartons from the less appealing “Check Locally” description on the How2Recycle label from the Sustainable Packaging Coalition to the coveted “Widely Recycled” category. Murosky answers Packaging Digest’s questions about the project. Why is it so important to qualify for the “Widely Recycled” claim? Murosky: We try to reduce our packaging materials sent to landfill. Zero waste is one of our 2020 goals, so we strive to design products and packaging that is recyclable or biodegradable.
Did you make any other changes to the packaging at the same time (graphics, for example)? Murosky: No other changes were made besides the paperboard substrate and coating. Our How2Recycle logo will need to be updated on the artwork, but we’re waiting to make that change because other artwork updates are in the pipeline for the fabric softener sheet cartons. [Editor’s note: All those updates will appear in 1Q2017.] Was the change a cost-neutral solution? Was that an important consideration in your decision to make the switch? Murosky: Yes, the change was cost neutral. As with any project, you want to keep cost increases to a minimum. However, as a company, we have an internal carbon tax that we use to fund packaging sustainability changes. Essentially that fund helps offset the price increase to new sustainable packaging components so that it does not affect margin. Luckily, in this case, we did not have a cost increase to offset. What other solutions did you consider and why didn’t you go with them? Murosky: No other solutions were considered. We would have stuck with our current poly coating if the project was not successful. Did your manufacturing partner [which Seventh Generation asked not to be named] have to make any changes to the packaging line because of the new cartons? Murosky: No line changes were needed. The new board substrate had no effect on packing line efficiencies or scrap. What tests did you do to ensure the new box was compatible with the product and protected it? Murosky: We have a vigorous qualification process at Seventh Generation. I put the product through a variety of tests to ensure that the new substrate preformed at parity or better to our current configuration. There was a: • Graphics review to ensure the new board substrate had the same print quality; • Box performance testing (carton drop tests, case drop tests, tear feature test, environmental chamber testing) to ensure that the board adequately protected the substrate (fabric softener sheets) and prevented oil migration; • Substrate compatibility testing to ensure that the mineralized poly-coating did not interact with our fabric softener sheets in any way. We also had each of our suppliers preform testing: • Converting (printing/cutting) trials at the carton supplier; • Packaging line trials and substrate compatibility evaluation at our manufacturing partner; • Third-party lab testing to evaluate board performance (oil resistance, water absorption, water-vapor transmission rate/WVTR). What did the results show regarding the package’s barrier properties? Murosky: The barrier properties of the EarthCoating performed better than our previous packaging, allowing us to confidently make the switch. Did you do any tests yourselves on the recyclability of the package or was that all handled as part of the How2Recycle label application process? Murosky: That was all handled by Smart Planet to receive the “Widely Recycled” logo certification from the Sustainable Packaging Coalition. How much did Walmart’s Sustainability Index, or the new Playbook, influence your decision to go with this particular package? Murosky: It actually didn’t really affect our decision. The project was basically complete when Walmart’s Sustainable Packaging Playbook came out. As a brand, we are always trying to push the limit on packaging sustainability and meet our 2020 sustainability goals. Where are your fabric softener sheets sold? Murosky: Across the USA. Our top buyers are Amazon, UNFI and Kehe. Do you plan to replace other cartons/boxes with this package? Murosky: Yes, we are looking into it for our two other poly-coated paper carton packaging configurations used for boxed powders: Natural Powdered Laundry Detergent and Auto Dish Powder.
BASF and Smart Planet Technologies target strategic partnership
Focus on Smart Planet Technologies` mineralized coating technology, EarthCoating® Ludwigshafen, Germany and Newport Beach, California – September 30, 2014 – BASF and Smart Planet Technologies are currently discussing a possible strategic partnership concerning the mineralized coating technology, EarthCoating®, for paper packaging applications. EarthCoating is a sustainable and cost efficient alternative to traditional extrusion applied coatings providing excellent barrier and heat seal performance and focusing on improving the recyclability of the packaging. It is engineered for processing within the traditional paper recycling infrastructure and can for example be used for folding cartons, detergent boxes, paper cups, paper plates, etc..
“EarthCoating is a long-awaited breakthrough technology for the packaging industry. A strategic partnership with BASF greatly advances the opportunities for the packaging industry to leverage EarthCoating towards greater sustainability in packaging applications,” said Will Lorenzi, President of Smart Planet Technologies.
“The search for more sustainable coating solutions has been growing in recent years and has become a priority for many companies involved in the paper packaging industry,” added Christian Schulz, Vice President, Center for Sustainable Paper Packaging within BASF.
By forming the Center for Sustainable Paper Packaging (CSPP) in 2013 BASF has committed itself to address these industry needs.
About BASF At BASF, we create chemistry – and have been doing so for 150 years. Our portfolio ranges from chemicals, plastics, performance products and crop protection products to oil and gas. As the world’s leading chemical company, we combine economic success with environmental protection and social responsibility. Through science and innovation, we enable our customers in nearly every industry to meet the current and future needs of society. Our products and solutions contribute to conserving resources, ensuring nutrition and improving quality of life. We have summed up this contribution in our corporate purpose: We create chemistry for a sustainable future. BASF had sales of about €74 billion in 2013 and over 112,000 employees as of the end of the year. BASF shares are traded on the stock exchanges in Frankfurt (BAS), London (BFA) and Zurich (AN). Further information on BASF is available on the Internet at www.basf.com
About Smart Planet Technologies Smart Planet Technologies is a packaging technology company with intellectual property focused on advancements in sustainability for the packaging industry. Our innovative technologies are focused on conserving precious natural resources and provide high quality, environmental alternatives across a wide variety of packaging applications. For more information, please visit our website at www.SmartPlanetTech.com
Media contacts BASF Andrea Hoerdt Global Communications Paper Chemicals Division Phone: +41 61 636 0644 andrea.hoerdt@basf.com
Smart Planet Technologies, Inc. Todd Gasparik Director of Marketing Phone: +1 949 610 7063 marketing@smartplanettech.com
EarthCoating Article, "Plastic Coatings, Step Aside"
Featured in Labels & Labeling Magazine
Spark of Innovation: An Interview with Christopher Tilton
ORANGE COUNTY REGISTER
Smart Planet Technologies is an intellectual property company focused on developing sustainable high-quality packaging materials.
• What project/research are you working on? Our primary focus is to develop recyclable, environmentally ethical alternative packaging materials. This is accomplished by replacing the plastic coating with mineral composites. By removing the plastic contamination from the packaging, they become 100 percent recyclable.
• What is your specific role in moving this project/research forward? My role includes developing, patenting and commercializing our core materials technology. I also work closely with our licensees’ engineers and manufacturing staff to support the implementation of our technology into existing industrial packaging plants.
• What would be the most successful outcome of your work, and what impact would it have on how we live? Billions of plastic-coated packages are sent to landfills every year. Unlike organic materials, which get broken down naturally by bacteria, plastic will remain in these fills for centuries. For example, coffee cups have plastic coatings that protect the paper from leaking and help seal the cup seams. Our research has developed low-cost, easily scalable materials that greatly reduce and replace the plastic contaminants with natural minerals. The mineral content allows the coatings to become compatible to the paper-recycling stream. Therefore, it is now possible to recycle billions of hot and cold cups rather than sending them off to landfills.
• What about this project is important to you personally? I now have the opportunity to provide the world with a material that can drastically improve the quality of our lives and the longevity of our planet. The most important aspect of my work is making sure I leave behind a legacy of innovation and ingenuity that will benefit my children’s world and help build a brighter future through the advancement of science and technology.
• What is the very best part of your job – when do you feel the most satisfaction?From supporting environmentally conscious companies in their efforts to take advantage of our technology.
• Why did you choose this career? As I began to understand the complexity of packaging, I realized that it is a great platform for innovation.
• Who or what inspired you to study in your field? The alarming truth is that almost every single product we buy comes in some type of packaging, and vast amounts of energy and resources are used to manufacture and dispose of packaging materials. My greatest inspiration is seeing my work and innovation combat these issues and offer real benefits to society.
• What makes you particularly well-suited to this work? I am stubborn. I, like most material scientists, have technical knowledge and engineering skills. However, it has been my willingness to try, fail and try again that has allowed me to achieve so much success.
• Where did you go to college? I graduated from Middle Tennessee State University with studies in Business and Agricultural Science. I was a Distinguished Military Science graduate and started my career as an Army officer.
• During high school and college, which courses helped best prepare you for your current position? My science and math courses were extremely interesting to me and contributed to my success. Also, the discipline and rigor of military training has proved to be invaluable throughout my career.
• What is the best advice you received that has helped further your career? Try to focus on work that you enjoy. Also, recognize that time, work and effort are needed to become proficient. Be willing to make the commitment necessary to the field you find most interesting, and become a subject-matter expert.
• What advice would you give, particularly to the student who may think math, science or engineering are “too hard” for him or her? Science is not easy; it takes commitment and hard work. I challenge students to be honest with themselves and recognize that they are more than capable, given an honest effort. It seems so easy just to avoid the “hard” classes and majors at school. But if you do, you’ll be closing the doorway to an exciting, rewarding and fulfilling career.
Whole Foods Moves to Mineralized EarthCoating for Deli Trays
As seen in Packaging World Magazine - http://www.packworld.com/sustainability/source-reduction/whole-foods-moves-mineralized-coating-deli-boxes
The Rocky Mountain Region of grocer Whole Foods Market plans to introduce its 100% recycled paperboard deli boxes with a coating made from 40% calcium carbonate.
By Anne Marie Mohan, Editor, Greener Package
“What I really want is a compostable coating that can be third party-certified as such and third party-certified as non-GMO,” McConnell says. “It would be a real game changer in the industry.”
The Rocky Mountain Region, which includes five states (Colorado, Idaho, Kansas, New Mexico, and Utah) and 28 stores, offers consumers two types of containers for use with its salad bar and hot food selections: a compostable wood fiber-based clamshell, and two sizes of the Bio-Plus Earth recycled paperboard containers from Fold-Pak. The 100% recycled-content Bio-Plus Earth® containers currently use a PE coating to provide leak-resistance and a grease barrier.
At Whole Foods’ request, Fold-Pak will provide the Bio-Plus Earth containers with Smart Planet’s EC-40 coating, which contains up to 60% less polymer content by weight than 100% low-density PE coatings while providing superior barrier properties to moisture, oil, grease, and fatty acids.
McConnell says his suppliers were receptive to the idea of experimenting with the new coating, and are currently in the process of fine-tuning the new solution. He says the new containers are expected to be available in Whole Foods’ Rocky Mountain Region stores within the next six weeks. Once implemented, the new containers will represent 1.5 million units/year.While McConnell says his ultimate goal for the paperboard deli-food packaging is certified compostability, the EarthCoating containers are a step forward. “We are working with two companies, Smart Planet and Fold-Pak, that are on a path that aligns with our core values,” he says. “Some people might call this a ‘less bad’ solution. I hate that terminology. I think it’s a ‘more good’ solution.
“If we waited for the perfect solution, we would have to say ‘no’ to suppliers all the time. They need the research and development dollars, they need someone to buy their product, and it’s an improvement over what was available previously. So we’re on the right path, and if it can get us to a compostable coating that is certified non-GMO, then that will be the ideal solution.”