As laminated plastics are often not able to be recycled, plastic packaging is considered an environment villain, especially for eco-conscious businesses. As a significant part of our operations, here at Law Print, we thought it was about time to look at the counter-arguments that suggest flexible packaging may not be as bad for the environment as initially portrayed.
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Given all the bad press surrounding plastics in packaging, many are surprised that the total volume of non-recyclable flexible packaging waste is only 1.6% of the total US annual waste. In the UK, packaging waste from all sources including industrial, commercial and household is less than 3% of total waste sent to landfill.
Using flexible films and laminates can significantly reduce environmental impact at the manufacturing stages. The amount of energy used in production/consumption has a less negative impact on the environment than traditional rigid packaging. So, although glass bottles can be reused and recycled, with flexible pouches the product to package ratio is 35 times greater than glass bottles. With more product and less packaging, landfill waste is significantly reduced.
These efficiencies also trickle down to distribution, with less space needed for transportation resulting in fewer CO2 emissions in transit.
When facts such as the above are presented, it starts to make the sustainability argument all the more complicated. In our latest infographic, we summarise some of the key facts and benefits of flexible packaging and how switching may benefit your business and the environment.
If you are looking to make the switch to flexible packaging then contact our team today. We can assist you from design consultancy to final store delivery.
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New and improved bioplastics are hitting the manufacturing world, seemingly, every week, but what about those that truly started the trend? Made from renewable sources and fully biodegradable, the original bioplastics offered an optimistic look at how packaging production could evolve but are we being too quick to forget about the likes of PLA, in the face of even more promising alternatives such as PHA?
PLA is a natural polyester commonly made from cornstarch or sugarcane. When ready to use, it has properties not dissimilar to polypropylene, polyethylene, or polystyrene.
First discovered all the way back in the s, by Wallace Corothers, the inventor of Nylon, PLA was never fully realised as a commercial material but by , it was the second most valuable bioplastic in the packaging market, according to consumption figures.
PLA is also known by the following monikers:
As with most bioplastics, a controlled environment that encourages fertilisation is needed for PLA synthesis to occur, but as opposed to needing bacteria to grow granules that can be harvested, as with PHA, carbohydrates are the most important element here.
Typically, cornstarch, sugarcane and tapioca starches are used, depending on manufacturer location. Starches are separated from the initial material, before being mixed with acid or enzymes and finally, heat, which allows dextrose to be isolated and this is where the magic happens. Fermentation of the dextrose leads to lactic acid production and that's the basic building block of commercially viable PLA. From here, polymerisation occurs so that volume can be multiplied and a finished bioplastic produced quickly and cost-effectively.
The following diagram breaks the process down into a simple visual:
Are you interested in learning more about PLA Flexible Film Manufacturer? Contact us today to secure an expert consultation!
Image from Bio Plastics news.Notably, PLA can be made using already in-situ manufacturing equipment originally designed to create petrochemical plastics, meaning that the price to switch over to a more responsible alternative is negligible and not a prohibitive reason to stall.
PLA is being used throughout multiple high-value industries, demonstrating a clear demand for bioplastic evolution. Thanks to the ease with which it can be made, using said existing equipment, manufacturers can offer an environmentally beneficial alternative to traditional plastics, which offers clients an opportunity to update their branding with greener marketing.
Current industry users include:
Food packaging: As a food packaging application, PLA is cost-effective and Generally Recognised as Safe (GRAS), though without additives it can be limited in the number of products it can be used to make. There is a risk of lactic acid leaching, when PLA comes into contact with certain liquids, though tests have indicated that levels are not harmful to humans. It has been used to produce cups, tea bags, bottled and films.
Medical: Similarly to PHA, PLA is bio compatible and can be used within the human body in the form of medical aids and support systems. The risk of infection is minimal and the range of applications is vast, from screws to plates and even tissue engineering. PLA dissolves in the body without toxic repercussions and is a lighter alternative to traditional metal.
Construction: A slightly tenuous one here. PLA can be used for very specific applications, such as insulation, but because it degrades fully, use is very limited right now. No structural uses are yet approved.
Textiles: As fabric composition continues to dominate the evolution of the fashion industry, PLA has risen through the ranks to become a viable alternative to synthetic polyesters. It is particularly useful for sportswear that requires high levels of breathability coupled with a lightweight feel, but its most industry-changing property is its recyclable nature. It has been heralded as a key player in the move towards a circular fashion economy.
Some of the largest manufacturers of PLA are:
A joint-venture between Cargill (US) and PTT (Thailand), NatureWorks has some very exciting ideas being tested. Already using plants in an earth-positive way, the company transforms greenhouse gases into sugars that can, eventually, be polymerised. This technology is being improved all the time and there is scope to negate the use of plants as well. Using abundant feedstocks, NatureWorks has, since , looked to keep improving the potential of PLA and today is highly respected for its flagship end product, Ingeo. It has a presence in more than 10 countries, supplying businesses in the US, Europe, Japan and Asia Pacific.
One of the leading manufacturers of now only reusable but also sustainable bags, WeforYou produces biopolymer shoppers in its facilities in China and supplies them throughout the world. The company speaks of a holistic approach from start to finish, which sees raw bio materials being transformed into a lasting and recyclable product.
Another joint venture, this time between Total (France) and Corbion (NL), Total-Corbion demonstrates an important shift in traditional production methodologies for existing petrochemical companies. Luminy® is the key offering here and comes in two formats, standard and high-heat applications. Created for a vast array of uses, it has already been utilised as food serviceware, food packaging and within the 3D-printing sector. The production facility is located in Thailand, with customers supplied globally.
There are many ways in which PLA is an environmentally superior alternative to standard plastics but the main benefits are reduced carbon footprints during production, cost-effectiveness of the switch to manufacture and of course, the recyclable nature at EOL. This being said, PLA isn't without its critics or downsides.
There's no denying that in comparison to regular plastics that have no option but to be sent to landfill at EOL, PLA is an attractive and environmentally aware response to a growing need. It's important to look at the full picture though, including criticisms, limitations and potential issues that stem from PLA use.
Taking hot food and beverages out of the equation, PLA is a great option for packaging materials, with the Food and Drug Administration (FDA) recognising it as suitable and safe. Applications are varied, ranging from plastic water bottles and cups to flexible films, extruded containers and moulded packages, such as yoghurt pots. Packaging should be used as a short-term food storage option, making it ideal for fresh and short shelf-life items.
Additives can be included to open up a wider array of packaging solutions, including those for high-heat applications, though this raises questions as to the environmental credentials of the finished product and can impact EOL responsibilities for manufacturers.
In short, yes. PLA should not be overlooked in terms of the impact it had on highlighting alternatives to traditional petrochemical plastics and though it has its critics and some would say it has been superseded by the likes of PHA, it is continuing to evolve. If its shortcomings linked to heat and easy recyclability can be improved upon, PLA could once again be hailed as a future solution that everybody needs to get onboard with. So perhaps the question should be: will PLA be the ultimate bioplastic that not only started but also ends the discussion about viable environmental packaging solutions?
Lead image by Kindel Media from Pexels
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