Life Cycle Assessment and Packaging Jon Dettling Olivier Jolliet

Director, US - Quantis [email protected] Co-founder – Quantis Professor – Univ. of Michigan [email protected]

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Life Cycle Assessment and Packaging

•Why LCA?: case study with polystyrene peanuts Packaging sustainability measurement and LCA: •What’s the function? •What packaging to consider? •Industry guidance •LCA and design •LCA and communication •The packaging context: end-of-life considerations

Intro.

Why LCA?

Function

What Pkg?

Design

What’s Really “Green?” • An increasing number of claims: • • • • • • • •

•

100% Recycled Recyclable Energy Efficient Organic XYZ-Free Reduced packaging Bio-based “Greener!”

How do we make sense of this?

•

We need a system to weigh all the competing factors.

3

Communicate

EoL

Case Study: Packing with Popcorn?

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Example LCA of packaging material: Polystyrene and Corn Popcorn Polystyrene: Non-renewable and non-biodegradable material What about real popcorn? Renewable and biodegradable How can we know which is really a better environmental choice? How do we measure this? What are the key factors to consider?

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Defining LCA Comprehensive evaluation of the environmental and human health impacts of a product, process, or service LCA is the only internationally accepted method for substantiating a claim or decision that one product, service or technology is environmentally preferable to another. (ISO 14040 series) 6

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

LCA phases and process Definition of objectives & system Inventory of resources & emissions

Impact Assessment

Application Interpretation

•Product development •Product improvement •Strategic planning •Marketing •Public policy-making

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

Renewable packing materials: system boundaries

EoL

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Advantage of LCA: See the whole picture

LCA prevents burden-shifting


From one life cycle stage to another
From one region to another
From one compartment (water, air, ground) to another
From one impact to another ...

Emissions displaced, not eliminated

www.quantis-intl.com

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

LCA Inventory

Emissions

Resources

Emissions

Resources

Emissions

Resources

Emissions

Resources

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Life Cycle Inventory Results Emissions Air CO2 Particles CO NH3 Water Nitrates Extractions Energy non renouv.

Popcorn g/kg

Polystyrene g/kg

620 0.2 1.0 3.1

5480 1.3 3.4 0.0

31 MJ/kg 7.2

0.0 MJ/kg 81.3

Which is better?

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

LCA Impact Assessment: Midpoint and Endpoint

e.g. IMPACT 2002+ Int J LCA 8 (6), 324-330 Int J LCA 9 (6), 394-404

EoL

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Popcorn impacts compared to Polystyrene impacts per kg materials

?

100%

Phosphates Nitrates NH3

80%

SO2

60%

NOx

40%

HC

20%

CO Part.

Ecopoints

Critical volumina

PC

PS

PC

PS

PC

PS

0%

N2O CO2

Critical surface-time

Popcorn is clearly the better choice for the environment

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Is this the right comparison to make? •

Is a comparison per kilogram per kg materials relevant? What is the packing trying to achieve? Adding mass? We need to define a “functional unit”, which gives us a proper basis for comparison To be effective, packing material must take up space and have properties to cushion against movement So our comparison is more relevant based on volume rather than mass

Phosphates Nitrates

100%

NOx

40%

HC

20%

CO

Ecopoints

• •

Part.

1 4

Critical volumina

PC

PS

PC

PS

0%

PC

•

SO2

60%

PS

•

NH3

80%

N2O CO2

Critical surface-time

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Popcorn impact compared to polystyrene impacts per m3 materials

Phosphates Nitrates

200%

NH3

150%

SO2 NOx

100%

HC 50%

CO Part.

Ecopoints

Critical volumina

PC

PS

PC

PS

PC

PS

0%

N2O CO2

Critical surface-time

By volume, polystyrene is the better choice for the environment

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Conclusions: Popcorn vs Polystyrene • “Natural” is different from “environmentally friendly” • Must consider whole life cycle and range of environmental impacts

• Impact assessment allows interpretation of results • Key parameters from an environmental point of view : •

density, number of reuse Material function or service is essential

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

LCA of Hand Drying Alternatives

1 7

EoL

LCA and Packaging

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

What is the Function of Packaging?

• To protect the product and deliver it to its site of use

-

It is therefore linked to the product amount / function If product is lost, more packaging and product must be produced to replace the function It is therefore necessary to consider the product’s life cycle when the rate of product lost might be altered

• Packaging can also have other functions (e.g. to act as a drinking container)

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Indirect impacts of packaging on product may matter: toothpaste Impact of wasted toothpaste is significant, but not enough to offset the benefit of new package

10 9

Energy (MJ)

8 7 6 5 4 3 2 1 0

Standard tube + carboard Toothpaste

Self standing tube Packing

Dosing tube

Toothpaste wastes

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Which Packaging to Consider?

Primary Packaging Switch

Causes Secondary Packaging Switch 2 1

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Which Packaging to Consider?

Secondary packaging 6 x the product mass 70 x the active substance mass

3

2

Sales representants Business travel Products Employees Raw materials Electricity

1

Buildings

Waste inceneration

Packaging

Site production

Transport

Energy production

Raw materials

0

Fossil fuel

R&D (energy)

kg CO 2 /kg product

4

CO2 at different cycle stages CO2Emissions Emissions at different Life Cycle life Stages Pharma Industry

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Life Cycle Boundary: Are you seeing the whole picture?

Sales reps

3

Business travel Products

2

Employees Raw materials Electricity

1

Buildings

Waste inceneration

Packaging

Site production

Transport

Energy production

Raw materials

0

Fossil fuel

R&D (energy)

kg CO 2 /kg product

4

CO2 Emissions at different life cycle stages Pharma Industry

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

What do we measure, is there industry guidance? • • • •

•

The Global CEO Forum has convened a “Global Packaging Project” in 2009-2010 with a focus on establishing common sustainability metrics for packaging Based heavily on Sustainable Packaging Coalition’s metrics, with heavier emphasis on LCA for environment Process now in a pilot phase with 18 value-chain pilots now underway Final output from the process planned for later in 2010

Wal-Mart’s Scorecard and Sustainability Consortium will also continue to set industry-wide focus

2 4

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Package design: Where do we focus? Supply chain operations ?

Choice of materials ?

Packaging ?

Impact of logistics ?

Form and features ?

Material weight ? End-of-life Management ?

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Where Should We Focus our Design and R&D?

2 6

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Idea & concept filtration w/ LCA Criteria: •Cost •Performance

•Environment can LCA te a evalu ate id cand ance rm perfo

LCA Informs creation of candidates and best strategies

LCA identifies best areas for action, DfE tools offer improvement guidance

LCA scenario simulations to help optimize design details

2 7

LCA supports communication on benefits of winning design

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Communication Example: NatureNes Baby Food

• Nestlé develops new baby food for European market

•

Includes:

• •

freshest ingredients new steam processing and preservation technology Unique Steam There is a desire to communicate Cooking on environmental benefits of new Process packaging (switched from glass): “Respect the “Respect the environment: Packaging reduces use of energy and emissions of CO2”

Simple Natural Recipes

2 8

2 8

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

The NaturNes Case Study Glass Jar components Steel PT Cap

Plastic Pot components Cardboard Cluster

Cardboard Cluster

PT = Press and Twist (Electrolytical tin plate, ETP)

Plastic (PP) Cap

(to group 2 jars, optional)

(to group 2 pots)

(Inside) Lidding film (PET-SiOx-OPA-PP Lid)

Paper Label

2 pieces of PP label

White glass Jar

Plastic (PP) Pot

Cardboard Tray (to group X clusters* )

Cardboard Tray

Cardboard Hood

(to group 3 clusters or 6 non-clustered jars)

(covering the Tray) * The number "X" of clusters per tray varies according to size and market

2 9

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

Main Contributors to Global Warming: Packaging Material and Distribution Plastic pot system with current logistics has longer transport distances

Plastic pot system used more efficient UHT stream process Plastic ……………………… has lesser impacts ……………………… to produce (for…… weight in package)

With “optimized” logistics network, the plastic would have an even greater advantage 3 0

EoL

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

How can we communicate this? Development

LCA

Spanish scenarios Baseline (green + red): 1010 km Expected (blue + red): 2083 km Optimised plastic (green + red): 1010 km

Epinal

System model Landfilling

Plastic Pots (simplified)

Sevares

Incineration

Recycling

1570 km Wastes

(Use)

Figures given here are only valid for 200g plastic pots sold i n Germany

8.7 g PP+EVOH

Distribution

Distribution

25% incineration in MWTP

75% substituting fuel or reducing agent in cement / steel industry

Electricity

0% recycled as plastic mixture

Collection/transport 20 km

Collection/Transport 20 km

Collection/Transport 20 km

2.19 g Inci neration of PP in municipal waste

6.51 g Plastic shredding and preparation

0g Recycling of PP

Elec: 13% LHV

- 4.17 Wh Electricity EU mix

- 29.9 kJ Heat, light fuel oil

0 MJ

-5.98 g Light fuel oil at regional storage

- 0g Virgin PP production

Capping, labelling and clustering

UHT process

*

Baby food

Filling and sealing

* *

Thermoforming

SiOx Lidding film on reels

*

Comparison on Terrestrial Acidification/Nutrification (one 200g jar or pot) + 254 kJ - 254 kJ for cement/ steel prod uction

End of Life

Trsp Packaging, coding

Steam

Functional unit 1 child meal packed & delivered

Heat: 26% LHV

+ 3.08 Wh + 21.8 kJ - 3.08 Wh - 21.8 kJ electricity heat

*

Pots ready on pallet

Container Assembly Use phase

0.009 Boundary Expansion

Distribution (Food)

Food Container Production

0.008

PP-EVOH-PP sheets on reels

Plastic caps

*

Cap / Pot Labels on tracer

Clusters

Trays and Hoods

LDPE film

(Pallets)

Raw material extraction, production, transports

Distribution (Packaging) On site Energy

0.007 Avoided burden

Other

0.006

Waste Treatment Waste Collection

0.005 kg SO2

Tray and Hood Stretch Film

0.004

Lid 0.003

Label Cluster

0.002

On site Water 0.001

Cap Pot or Jar

0

Germany

Spain

France

Before Supplier Transports Recycling and Heat Recovery

-0.001 Glass jars, Plastic pots, Plastic pots, Glass jars, Plastic pots, Plastic pots, Glass jars, Glass jars, Plastic pots, 200g, DE 200g, DE 200g, DE 200g, ES 200g, ES 200g, ES 200g, FR 200g, FR 200g, FR OPT OPT OPT

Review Panel, ISO 14040

Scientific 3 Publication 1

Labeling: “Reduces Energy Use and CO2”

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

What is the geography and context of the packaging? • Consumer behavior and public policy can influence environmental performance • A packaging that is “environmentally friendly in one country may not be in another • Consumers may recycle at very different rates • Infrastructure may not exist to handle recycled materials in some locations • Policies effect rates of recycling and incineration vs. landfill

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Is it better to recycle or recover energy? Avoided mtrl

Avoided heat Plastic replacing virgin material Plastic virgin plastic biofuel or fossils Plastic replacing other materials Plastic wood biofuel or fossils

Avoided electr.

Tot. GWP energy

biofuel or R fossil

R

-

I

I

Paper/cardboard replacing cardboard vs biofuels Paper wood biofuel biofuels R

R

Paper/cardboard replacing fossil heat or electricity Paper wood fossil fossil I

I

Adapted from Anna Björklund & Göran Finnveden

Whether to recycle can depend on what is replaced Whether to recovery energy can depend on the alternate fuel

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

Example: California’s beverage container recovery program • • • •

A successful program has greatly boosted rates of recovery? But what do we do with the containers? What end-markets should be developed to provide most environmental benefit? These end-markets will also determine which packaging options perform best within California

3 4

EoL

Intro.

Why LCA?

Function

What Pkg?

Design

Communicate

EoL

Summary of Key Points: •

To judge environmental performance, we must take a life cycle perspective

-

• • • • • • •

Categorical information like “recycled” or “bio-based” is not sufficient

LCA gives a credible and scientific basis to environmental decisions and claims Packaging LCAs must consider the function of packaging and perhaps of the product The full packaging system should be considered Industry standard and coordination are emerging LCA can help guide development of better packaging solutions LCA can provide credibility to a marketing claim The context can be as important as the packaging

Questions?

Jon Dettling Director Quantis US

Olivier Jolliet Co-founder, Quantis Professor, Univ. of Michigan

[email protected]

[email protected]