Packaging Sustainability is maturing. Product manufacturers, distribution experts, and consumers are driving substantial changes in raw material sourcing, manufacturing, packaging, and distribution practices.

1. THE UPSIDE OF PACKAGING SUSTAINABILITY
SEPTEMBER 2011

2. Packaging Sustainability is maturing. The green movement of recent years has taken root with consumers, product
manufacturers, and distribution experts to drive substantial changes in raw material sourcing, manufacturing,
packaging and distribution practices. Yet, it remains a multi-dimensional, complex science. We’re seeing
advancements in packaging reduction, material substitutions, recyclability and use of recycled content, renewable
energy, transportation, truth in advertising, ethical sourcing, and social responsibility. These improvements are
important, but generally carry a price tag. The most attractive solutions are those that improve sustainability but
actually result in economic savings – savings that ripple through the system to increase profitability.
Product manufacturers are supporting the cause through Life Cycle Assessments. Consumer electronics products are
becoming smaller and lighter in a process known as “dematerialization” where products require fewer resources to
manufacture, less packaging, less energy to transport, and are easier to recycle or repurpose at the end of life. 1 In
the case of one product, styrofoam and traditional packaging were replaced with a protective bag made of
recycled materials, packing three-to-a-case, which reduced total product packaging by 97 percent.2 Concentrated
liquid soaps, detergents and cleaning products are in; phosphates are out. More and more containers are now
refillable and reusable.
When considering raw materials for packaging, poly coatings, waxes and laminates often complicate package
recyclability. These are being replaced with aqueous coatings which are recyclable and/or compostable. Bio
based materials such as PLA (poly-lactic acid) are gaining momentum, however, it’s important to note that while
some bio-based packaging materials may be biodegradable, not all biodegradable materials are bio-based.3
As fuel costs have skyrocketed once again, retailers are reminded of the need for better efficiencies in shipping and
distribution. Unfortunately, most shipping containers cube out before they weigh out, that is, they’re carrying a lot
of unnecessary air. Existing products can sometimes be reconfigured to stack more efficiently, adding additional
rows and filling out the pallet while also improving stabilization.
Load planning software from CAPE Systems4 and TOPS Engineering5 are effective tools for palletizing optimization.
In this process, however, primary package sizes are often determined first, then cases, pallets and container loads
are configured from there. The result is potential inefficiency in the final load. Reverse engineering starts with the
dimensions of a truck or shipping container and works backward through the process so that the primary package
is fully optimized by weight and volume. Think of it as a harmonization of primary, secondary,
THE UPSIDE OF PACKAGING SUSTAINABILITY
PACKAGING
2100 GATEWAY BLVD. HEBRON, KY 41048 WWW.ZUMBIEL.COM
PACKAGING
Packaging Sustainability is maturing. The green movement of recent years has
taken root with consumers, product manufacturers, and distribution experts to
drive substantial changes in raw material sourcing, manufacturing, packaging
and distribution practices. Yet, it remains a multi-dimensional, complex science.

3. and tertiary packaging where each component shares the load as part of an engineered system. Selling Unit Cube
Utilization is important at the store shelf, but Transport Unit Cube Utilization (cases, pallets and shipping containers)
is equally critical but often unseen and unappreciated by consumers. Pallets are becoming stronger and are
sometimes reusable. Reusable trays, totes, tier sheets, and even corrugated RSC’s extend the practical life of
secondary packaging and dunnage. Repulpable paper strapping materials are supplanting plastic or metal and
pallet loads are being secured with thin, low density films with as much as 250% stretch, providing full protection
with a greatly reduced packaging footprint.6
A current trend supports the reduction, elimination, or repurposing of corrugated shipping cases. With Retail Ready
Packaging (RRP), a new generation of ingenious cases double as point-of-purchase trays with beautiful graphics,
thus allowing for fewer “touches” in handling. Pouches can be interleaved and split to create top and bottom
display trays from a single case. Small items with high volume are key targets as the ergonomics of stocking
shelves is also evolving.
Bag-in-box technologies aren’t just for wine anymore. Other liquids such as motor oil are finding a home in these
squared-off structures which have far better cube utilization and produce 84% less waste than with rounded
polyethylene alternatives.7
Protective cushioning materials such as Styrofoam are being replaced by air bags, bio-based materials such as
water soluble starch, plant byproducts such as coconut husks,8 and recyclable expanded paper structures.9 Bags
made of polyvinyl chloride (PVC) are being eliminated altogether in favor of recyclable paper bands and strapping.
Back at the package converting plant, other exciting changes are also taking place. Hybrid processes can combine
two or more printing processes such as flexo, offset, digital and rotary screen printing with die cutting, gluing, and
package assembly. Advancements in prepress, prototyping, plates and inks are all being made with sustainability
in mind.
IN OTHER NEWS. . .
Walmart Stores, Inc. continues to provide strong leadership in Packaging Sustainability. The Sixth Annual
Packaging Sustainability Expo was completed in April, 2011 with approximately 2000 attendees and exhibitors
gathering in Arkansas to exchange success stories and capture the latest information from industry experts. The
Walmart Packaging Scorecard is progressing as the US-EPA is in the process of providing updated life cycle
inventory data for virgin and recycled plastics, PLA, aluminum, steel, glass, paper and paperboard. Refinements to
the scorecard are also coming in the areas of cube utilization, sustainable material metrics, and improvements to
the reporting functions for total material usage, GHG emissions, CO2 equivalents, and calculations per the
Consumer Meaningful Unit of Measure (CMUM).
Virtually every raw material supplier, product manufacturer, packaging and supply chain organization has joined
the Green Movement by word if not in deed as evidenced by web sites and annual reports. Consumers are highly
influenced to make purchasing decisions based on product labeling, therefore, products that claim to be
eco-friendly are often favored. Environmental marketing claims are required to meet state and federal requirements,
yet violations abound. Deceptive advertising and unsubstantiated claims have been seriously problematic. The
Federal Trade Commission is responsible for regulating these claims and to that end, has issued a revised set of
“Green Guides” for product labeling.10 NGO’s such as Greener Package provide third-party reviews to assist with
this compliance.
How do individuals and organizations sort through the confusion? The Global Packaging Project is a program of
the Consumer Goods Forum that seeks to simplify the complicated details of packaging sustainability.11 Led by
Unilever and Tesco, a large representation of manufacturers, retailers, packaging companies, associations,
academic and technical organizations are working to develop a common, international language, metrics and
protocol to clarify such terms as “sustainable sourcing”, “compostable”, “biodegradable”, “renewable”, etc. The
2100 GATEWAY BLVD. HEBRON, KY 41048 WWW.ZUMBIEL.COM
PACKAGING

4. • Electronics
• Food, Beverage and Agriculture
• Home & Personal Care
• Paper
• Packaging
study includes environmental attributes, life cycle assessment, economic and social indicators. The tools will be
user-friendly, employing more accurate data than is often currently available. A second version of the protocol is
nearing release.
On a broader scale, the Sustainability Consortium (TSC) is an independent organization of global participants that
have recently formed to promote sustainability with products, consumption, and supply chains. It reaches beyond
packaging to develop strategic partnerships, measurement, reporting standards, and conduct scientific research.
TSC market sectors include:
Formed in 2009, the organization currently holds 77 member companies and academic partners.12
So show me the money! There are treasures in sustainable packaging through changes in raw material, quality
and productivity improvements, and increased partnerships with a groundswell of CPG companies and consumers
who are driving the train.
We live in exciting times. The dynamic science of sustainability marches on. Fortunately, sustainable packaging
doesn’t preclude profitability. As packaging professionals, it’s essential to be actively engaged as we sort through
the clutter and search for meaningful improvements that can also add to the bottom line.
WRITTEN BY: DAN MALENKE
Dan Malenke is an accomplished training manager with extensive coast-to-coast and international experience in
developing and directing technical seminars for the printing and packaging industries. His career includes 20+
years with a Fortune 500 company, 9 years university teaching experience, and accumulated work in production.
ABOUT ZUMBIEL PACKAGING
Established in 1843, Zumbiel Packaging has been providing innovative paperboards packaging solutions to
brands in the beverage, automotive, and consumer markets. The privately owned and operated company, located
in Hebron, Kentucky, is one of the largest paperboard packaging companies in the United States. For more
information on Zumbiel Packaging please visit www.Zumbiel.com.
2100 GATEWAY BLVD. HEBRON, KY 41048 WWW.ZUMBIEL.COM
PACKAGING

5. REFERENCES
1 Consumer Electronics Association, “Sustainability Report” 2010,
http://www.ce.org/GovernmentAffairs/2267.asp
2 Walmart Stores, “Home Entertainment Design Challenge”,
http://walmartstores.com/Sustainability/8600.aspx?p=7983
3 Weber, C. J., Haugaard, V., Festersen, R., & Bertelsen, G. (2002). Production and applications of biobased
packaging materials for the food industry. Food Additives and Contaminants, 19, 172–177.
4 Cape Systems, “Pallet Lite, Cape Pack, and Truckfill”, http://www.capesystems.co.uk/
5 Tops Engineering, “MaxLoad® Pro”, http://www.topseng.com/MaxLoadFeatures.html
6 Collins, Mark,“Stretch Your Imagination”, Material Handling and Logistics, March 1, 2010
http://mhlnews.com/packaging/stretch-imagination-6862/
7 Greener Package, “Bag-in-box for Motor Oil”
http://www.greenerpackage.com/source_reduction/bag--box_motor_oil
8 Greener Design, “Coconut Husks Find New Life as Packaging”
http://www.greenbiz.com/news/2010/09/20/coconut-husks-find-new-life-packaging
9 ExpandOS™, “Alternative Product Protection System” http://www.expandos.com/
10 Federal Trade Commission, Green Guides, “ Proposed Revisions to Claims Currently Addressed by Guides”,
2010, http://www.ftc.gov/bcp/edu/microsites/energy/documents/Green-Guides-Summary-of-Proposal.pdf
11 Consumer Goods Forum, “A Global Language for Packaging and Sustainability”
http://www.vics.org/docs/KSurvey/press_releases/pdf/GPP_FinalReport_170610.pdf
12 The Sustainability Consortium, “Science and Tools that Improve Product Sustainability”
http://www.sustainabilityconsortium.org/
2100 GATEWAY BLVD. HEBRON, KY 41048 WWW.ZUMBIEL.COM
PACKAGING