Sustainable Packaging Solutions for Edible Commodities ... - PackPlus
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Sustainable Packaging Solutions for Edible Commodities ... - PackPlus

Sustainable Packaging Solutions for Edible Commodities ... - PackPlus Sustainable Packaging Solutions for Edible Commodities ... - PackPlus

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12.07.2015 Views

<strong>Sustainable</strong> <strong>Packaging</strong> <strong>Solutions</strong>For <strong>Edible</strong> <strong>Commodities</strong>With PolyolefinsDr U.K. Saroop, Vice PresidentBusiness Development, PolymersReliance Industries Limited2Package Conference9 th July 2009, New Delhi2

Agenda Dimensions of Sustainability :Economy, Society & Environment Polyolefins Case Studiesi) PWSii) Lenoiii) Atta <strong>Packaging</strong>iv) Milk <strong>Packaging</strong>v) Bubble Guardvi) Malt Milk Foods Recycling3

Sustainability - Environmental& Community Stewardship<strong>Sustainable</strong> Development:“Meeting the needs of the present without compromising theability of future generations to meet their own needs.”- Norwegian Prime Minister Gro Harlem Brundtland (1980)& used by the World Business Council(Source: HBR, Dec 06)Indian Plastic Industry – to take the lead4

EconomySocietyEnvironment5

Next Wave of GlobalisationBy 2013• Output of the global economy would cross US$ 75 Trillion (PPP Basis)• 15% of global population( ~1.2 bn people) in the developing countries to joinglobal middle class3 key features• Growing economic weight of the developingcountries – emergence of trading power houses likeChina, India & Brazil• Potential <strong>for</strong> increased productivity - offered byglobal production chains• Accelerated diffusion of technology - madepossible through falling communication costs andimproved accessSource: World Bank report “Global Economic Prospects – managing the next wave of globalization”Deeper integration with world economy through Plastics6

Indian Economy: Growth IndicatorsBy 2020• Productivity growth to help India sustain> 8% growth• Per Capita GDP (in US$) will Quadruple• Indians will buy 5 times more cars and consume3 times more Crude Oil• > 100 million people will enter labour <strong>for</strong>ce• 140 million rural dwellers to move to urbanareasSource: Goldman SachsIndia to over take USA by 20507

Agriculture: India Food Landscape• Low Productivity :40-50% of worldaverage• Heavy Pre and Post harvest losses– Food Grains : 10-20%– Fruits & Vegetables : 30-35%• Land getting uncultivable due tosanitation & Water Logging• With increasing demand food Supplywill be under stress• Efficient production and betterconservation is the key to reduce stress(Source: world Agriculture: FAO Report June 2006)Plastics to play key role in Pre-harvest, <strong>Packaging</strong> &Transportation to reduce “Food Stress”8

Water: Indian Scenario -Heading towards Stressed SupplyYearPopulationCr.Available Water(Cum/Capita)Remarks1991 84.6 2209 No Stress2000 100.2 1865 No Stress2025 139.3 1342 Stress• Per Capita Water Availability decreasing• 9000 cum/yr/capita in 1990• 5100 cum/yr/capita in 2015• 70% of Surface water resources arepolluted by biological and toxic pollutants• Ground Water levels falling by 2.5m/yr insouth India(Journal of Indian Water Works Association(Global Average)1000 liter water needed to grow 1kg Grains9

<strong>Sustainable</strong> Water• India amongst High water poverty nations• Irrigation water withdrawal is 558 bcumagainst requirement of 303 bcum• Farming consumes 70% of naturalreplenished waterIMPLIES• Use of Micro and Drip Irrigation• Plastic Crop covers to reduce evaporation• Rain Water Harvesting Systems(Journal of Indian Water Works Association)Gravity fed drip irrigation system to reduce agricultural waterconsumption by 50%10

Plastic Industry :Socio-Economic Contributions• Delivering Efficient management of scarce resources Optimizing the benefits obtained fromdepleting natural resources Improvements to the human health madethrough its products (Pharma & Others)• Innovating New Products that meet customer needs Processes that reduce risks to health andEnvironment Routes of reprocessing and recyclingNeed to create Public Awareness11

EmploymentThe challenge in front of Industry• Expand Opportunities <strong>for</strong> the growingPopulation• Enrich Knowledge and skills througheducation• Raise the living standards of employees• Make provisions <strong>for</strong> a good life aheadIndustries ready to take challenge• Plastics, Agro, Retail, Tourism,Healthcare, Communication, Educationand Financial ServicesPlastics Industry the <strong>for</strong>erunner12

Climate Change: Towering Indicators• 11 of the past 12 years yrs –warmest since 1850• Even if emissions are reducedimmediately, climate change willcontinue <strong>for</strong> centuries• Over next 20 years, globaltemperature to rise @ avg. 0.2°C• Temperature to rise by 7 to 8°Cduring 21 st century• Sea level to rise by 30-40 cmsduring 21 st century(Source: Scientific American)Climate Change – sparking events, that haven't happened in650,000 years13

Energy Stress: Heading towardsEnergy & Emission CrisisOil & Gas provides 60% of world’s energy• 2030 world energy requirement•850 Quadrillion BTU/yr•against present•500 Quadrillion BTU/yr• Massive new investments required to developand deliver energy• Considerable stress on existing sourcesEffect on Environment• CO2 emissions projected to go up to50BnMT from today’s 30BnMTPlastics to reduce the Energy Stress and Emission14

Emissions :Industry & Green House GassesWorld energy-relatedCO2 emissions by sector 2004:other8%Residential13%Industry18%Transportation20%PowerGeneration41%CO 2 emissions Industry contributes to only 18% Power 40% & Transportation 20%Total = 26.08 billion metric tons(Source: International Energy Agency)Industry – one of the least contributor to GHG15

Preamble to Innovation• Use of Expertise and Skillsacquired by Plastic Industry <strong>for</strong>the benefit of Society throughInnovationsInnovation the first step towards <strong>Sustainable</strong> Future16

Polyolefin17

Global Demand - PlasticsWorld Polymer Demand ~ 190 MMTLLDPE11%LDPE10%PP24%ABSHDPE17%PC2%7%PET19%PVC4%6%PSSource: CMAI 2009Polyolefin constitutes >60% of Polymer demand18

Global Polyolefin Demand1600001400001200001000008000060000400002000001184667170917MMT61005903442008 2013PPPEPO - CARG 5.2%PO are growing at higher rates than other PolymersSource: CMAI 200919

Polyolefins - IndiaPolyolefins Capacity in IndiaHPL18%GAIL8%RIL74%RIL Major player in India20

Indian Plastic Industry:Key Growth SectorsPotential bySector2012-13(MMT)<strong>Packaging</strong> 6.2Infrastructure 2.5Agriculture 1.0Consumer Goods 0.5Health Care 0.2Others (Including Housewares) 2.1Total 12.5<strong>Packaging</strong> accounts <strong>for</strong> half of plastic consumption21

PP - A Versatile PolymerWith widest Per<strong>for</strong>mance EnvelopeIzod impact at RT, J/m2Izod impact at RT, J/m2600 600Optimum Optimum impact-stiffness impact-stiffness balance balance4004002002000 01000 20001000 2000Flexural modulus, MPaFlexural modulus, MPa22

<strong>Packaging</strong> –Revolutionizing Classical 4 “P” Model<strong>Packaging</strong> – Adding the 5th Dimension23

Life Cycle AnalysisEnergyRawMaterialEmissionsManufactureRaw MaterialsProductWasteWaterUseDisposalHealth Hazard<strong>Packaging</strong> encompasses• Raw Material• Processing• Formulating or Compounding• Use• Waste Management24

Case Study – Plastic Woven Sacks25

PWS <strong>for</strong> Food grains & Sugar <strong>Packaging</strong><strong>Packaging</strong> and storage of Foodgrains & Sugar is achallenging job.Both are hygroscopic and thermally active.Ideal <strong>Packaging</strong> System should have : Adequate Mechanicals. Sustain the quality on long term storage26

The <strong>Packaging</strong> material should have– Resistance to moisture– Resistance to air (but need not be ideally airtight)– Poor thermal conductivity.PWS is an ideal medium due to its better resistance tomoisture, air and very low conductivity.27

Criteria <strong>for</strong> designing <strong>Packaging</strong> mediaSufficient TensilePropertiesWeather Resistance(UV)PP WOVEN SACKSResistant to handlingabuses - viz. MultipleHook & ParkhiInsertionConducive to grainMetabolism i.e.Dissipationof moisture &temperature.28

PWS <strong>for</strong> Food grains & Sugar <strong>Packaging</strong>Extensive trials <strong>for</strong> <strong>Edible</strong> commodities taken to stabilize use ofPWS. Some of commodities packed in PWS•Sugar• Food Grains•Pulses•Oilseeds• Cattle feed•Tea• Coffee Beans•Rice29

PWS – Per<strong>for</strong>mances30

BIS Specification on Food grainBIS Specification - IS 14887:2000Textiles - High Density Polyethylene ( HDPE)/Polypropylene (PP) Woven Sacks <strong>for</strong> packing 50 kg/ 25 kg Food grains - Specification31

ISO Specification onFood grain <strong>Packaging</strong>ISO Approved Internationalstandard of “PWS <strong>for</strong> packagingof Foodstuff” with no negativevotingA Reliance Initiative32

PWS Life Cycle Analysis ILife Cycle data <strong>for</strong> <strong>Packaging</strong> of 1 Million Tonnes of Bulk <strong>Commodities</strong>MaterialReqd. (MT)Energy( 000s GJ)JUTE12290Water ( 000sLac Ltr)Chemical(MT)Energy( 000s GJ)PAPERWater ( 000sLac Ltr)Chemical(MT)Energy( 000s GJ)PP-HDPEWater ( 000sLac Ltr)Chemical(MT)Phase I(Prod. OfRaw153.6 12 258.5 612 18 4647 178.3 1.4 0.014Material)Phase II(Production 179.4 9.7 Negligible 57.6 Negligible Negligible 48.5 1 Negligibleof Sacks)Total 333 21.7 258.5 669.6 18 4647 226.8 2.4 0.01472002310Plastic production conserves Energy, Water & Chemicals33

PWS Life Cycle Analysis IITo transport 350 Million Tonnes of commodities in Jute & Paper whencompared to PP-HDPE woven sacks400000391422Additional No. of Trips30000020000010000001784000Jute PWS Paper140001200012833Excess Fuel1000080006000400020000 58.50Jute PWS PaperPlastic products use conserves Energy at each value chain34

Case Study – Leno35

Leno Bags – The Ideal Choice <strong>for</strong> F & VIt is a <strong>for</strong>m of weave in which adjacent PP warp tapes are twisted aroundconsecutive weft tapes to <strong>for</strong>m a spiral pair, effectively locking each weftin place.36

Advantages of Leno Bags Excellent breathability, good tensile & burststrength. Used <strong>for</strong> onions, potatoes, garlic, cabbage, beetroot, brinjal, carrot and coconuts. Can be printed & labeled. Available in wide range of colours. Light in weight & cost effective compared to jutebags. Does not impart odour to packed contents Capacity : 1 to 50 Kg.37

Leno Bags <strong>for</strong> Potato Storage• India 3 rd largest producer of potatoes.• Leno provides better aeration to produce• Most suitable <strong>for</strong> Cold Storages reduces powerconsumption by 30%.• Can be stored @ 10-12 o C instead of 2-4 o C• Leno and CIPC – to create synergy <strong>for</strong> storagepackaging.• No sweating of potatoes hence lower wastage• Ideal <strong>for</strong> sweat less potatoes due to controlledsugar level in potatoes.Huge Savings ~ 28 Million Tonnes of Potatoes produced in India38

Case Study – Atta <strong>Packaging</strong>39

Atta <strong>Packaging</strong>• India produced 74 million tons of wheat last year,which is about 35% of India's total food grainproduction of 212 million tonnes.• There are around 200 large flourmills in India, witha milling capacity of around 15 million tonnes• Potential <strong>for</strong> packaging lies in consumer packs <strong>for</strong>packing atta in 1, 2, 5 and 10 Kg packs.40

Atta <strong>Packaging</strong>• 20% of 74 MMT is packaged – 14.8 MMT• No. of bags required – 1.48 Bn bags• Wt of 10 Kg bag (PET / Poly laminate) – 55 gms• Total Polymer requirement – 81.4 KT• PE required (85% of total laminate) – 69.2 KT• M-LLDPE ( 33% of total PE) – 22.8 KTIf 20% of atta is packed PE requirement estimated to be 69 KT& m-LL requirement of 23 KT41

Life Cycle Analysis <strong>for</strong> <strong>Packaging</strong>- 1 lac ton of wheat flourJute BagPlastic Film BagMaterial Required (Mt) 1960 680Phase I: Production ofRaw MaterialPhase II: Production ofBags & LinersEnergy(thousand GJ)Water(ThousandTons)Energy(Thousand GJ)Water(ThousandTons)21.50 1677 38.36 264.047.19 1506 24.22 296.0Total 68.69 3183 62.58 560.0Phase III:DistributionFuel (Tons)4663Jute BagEnergy (GJ)261.29FuelPlastic Film BagEnergyTaken as BasisHuge Saving at each stage in Value Chain42

Life Cycle Analysis <strong>for</strong> <strong>Packaging</strong>- 1 lac ton of wheat flour (cont.)Phase IV: WasteManagementJute BagPlastic Film BagsRecyclingPercentEnergy SavingsEnergy Savings(thousand GJ/680ton)100% 17.20Not Applicable80% 13.76IncinerationEnergy RecoveredEnergy Recovered(thousand GJ/680ton)100% 35.24Not Applicable80% 28.1243

Life Cycle Analysis <strong>for</strong> <strong>Packaging</strong>- 1 lac ton of wheat flour (cont.)Air EmissionsJute BagPlastic FilmBagCO kg 54.3 0.6CO 2kg 6610.2 760.0SO xkg 134.8 5.2NO xkg 68.1 4.8CH 4kg 39.5 3.2HCl kg 5.3 0.0Dust kg 67.6 1.4Water EmissionSuspendedSolidskg 352.3 0.2Chlorides kg 4535.5 0.1Lower Emission levels in Plastic Bag44

Case Study – Milk <strong>Packaging</strong>45

Milk <strong>Packaging</strong>Burfi Peda G’Jamun Kalakand Kunda KhurchanKulfi Rabri Basundi Khoa• Chakka• ShrikhandGheeButterMalai• Curd• Yoghart• Lassi•ChaasFat RichProductCulturedProductHeatDesiccatedProductsMILKAcid-HeatCoagulatedProductMilk basedDessertsPaneer•Kheer• Payasam•Phirni•Ghevar•Sevian• Sohan Halwa• Gajar Halwa• Cashew BarfiChhanaFlavouredMilkFresh MilkRasgolla , Sandesh , Rosomalai , Chhana Murki,Chhana Polao , Pantua46

Milk <strong>Packaging</strong>Milk <strong>Packaging</strong> in flexible pouches growing at 12-15%47

Milk <strong>Packaging</strong>Durable Goods4 paiseRecreation 6paiseTransport4 paiseGross Rent 3 paiseMeat, Eggs, Fish 6%Sugar 3%Salt / Spices4%Fruits andNuts 4%Medical Care7 paiselothing andFootwear 8paiseFood, Beverages,Tobacco51 paisePulses 6%Beverages 10%<strong>Edible</strong> Oils8%Vegetables 12%Cereals(31%)Miscellaneous 17paiseMilk and MilkProducts(16 %)Source : Dairy India Yearbook~8% of Total Expenditure on Milk48

Milk <strong>Packaging</strong>Glass bottle Vs Plastic Pouch- 300% more in terms of weight of packaging- 150% more in terms of volume- 100% more in terms of energy consumption• Weight of a glass bottle : 200 grams (500 ml)• Weight of a plastic pouch: 4.0 grams (500 ml)Glass Plasticmilk-53% milk-93%Resource Saving Features of Plastics49

Life Cycle Analysis <strong>for</strong> <strong>Packaging</strong>- 1 Lac Litres of MilkGlassPlastic PouchMaterial Required (Mt) 45.4 0.40Energy* Water* Energy* Water*Phase I: Production of RawMaterialPhase II:Production ofBottles/Pouches671.92 32.221608.0530.27 4.5625.6Total 1202.19 1608.0 36.78 25.6GlassPlastic PouchPhase III:Filling &DistributionFuel*Energy*Single [Return]Fuel*Energy*Single [Return]2049114.75 [213.43]112062.73 [106.64]*Units: Energy (GJ), Water (Thousand Litres), Fuel (Litres)Huge Saving at each stage in Value Chain50

Life Cycle Analysis <strong>for</strong> <strong>Packaging</strong>- 1 Lac Litres of Milk (contd.)Phase IV: WasteManagementRecyclingPercentGlassEnergy Consumption*Plastic PouchEnergy Consumption*100% 501.67 4.5680% 401.34 3.6560% 301.00 2.7450% 250.83 2.28Reuse (IncludingTransportation)Energy*ConsumptionWater*Consumption95% 277.8 509.180% 457.5 675.460% 697.0 897.2Energy*Consumption143.4(New PlasticPouches)Water*ConsumptionIncineration Energy Recovered* Energy Recovered*100% 20.73Not Applicable80% 16.5825.6(New PlasticPouches)*Units: Energy (GJ), Water (Thousand Litres), Fuel (Litres)Saving in Recycling & Waste Management also51

Emissions during Phase I & II<strong>for</strong> 1 Lac Litres of MilkGlassLDPEAir EmissionsCO kg 54.3 0.6CO 2kg 6610.2 760.0SO xkg 134.8 5.2NO xkg 68.1 4.8CH 4kg 39.5 3.2HCl kg 5.3 0.0Dust kg 67.6 1.4Water EmissionSuspendedSolids kg 352.3 0.2Chlorides kg 4535.5 0.1Lower emission in Packing One Lac Litres of Milk52

Case Study – Bubble Guard53

Bubble Guard Printed Cartons• Branding (Better visibility on Shelf)• Durable• Moisture ProofApple <strong>Packaging</strong> in Bubble Guard• Light Weight• RecyclableDabur Honey <strong>for</strong> Export in Bubble Guard Pkg.54

Bubble Guard Returnable <strong>Packaging</strong>• Environment friendly• 100% recyclable & reusable.• Improve Shelf Life• Moisture Proof, Better Aesthetics• Conserving natural resources• Replaces paper cartons• Replaces Plywood & WoodUse of Polymer in place of Paperwill reduce De<strong>for</strong>estation & reduceCO2 emissions55

Malt Milk Foods – Glass to PPAvg. weight of 500 gm BottleGlass : ~ 330 gmPP : ~ 50 gmHuge Saving in Energy & Transport Cost56

RecyclingThe most preferred option …For Waste Management57

Plastic Fantastic• Reduced total material requirement• Low energy requirement in production• Less fuel consumed in transportation• Pollutants at minuscule level (Both during production & recycling)• Minimal waste at the end of life due to recyclabilityImproving quality of life through protection & conservation58

Integrated Waste Management -Imperative• IWM system - to manage waste in an environmentally & economicallysustainable way• Cost effective option in-lieu of traditional methods of Landfill• Addresses - energy from Waste, Value added products, Public Education &Shared Responsibility• Participants – Plastics Value Chain,• Consumers & Local Government• Aimed at - increased recycling & energy recoveryAn issue that needs to be addressed effectively...59

A Three Pronged ApproachUnconventionalRecyclingInnovative & cost effective commercial solution60

Carbon Recycling:Fuel from Plastic WasteWaste to Diesel:• 1 MT waste yielding 900 ltrs of Diesel• Con<strong>for</strong>ming to Highest Quality EN 590 diesel• Patented ProcessGR Technologies,KoreaAxiom Energy Ltd.,AustraliaEnergy-Han<strong>for</strong>d,Cali<strong>for</strong>niaCarbon Recycling – <strong>for</strong> green energy61

Unconventional Recycling:Road Network Essential <strong>for</strong> Growth• 2 nd Largest road network in the world• Total network of 3.3 million km• USA (6.4 million km) & China (1.8 million km)• Highway network density (km/ sq. km of land)• India: 0.66 – comparable to USA (0.65)• Far better than China (0.16) & Brazil (0.2)• Accounts <strong>for</strong> India’s -• 90% of passenger traffic• 65% of total fright (~ 960 million tons / km-yr.)Source: World BankBut … Annual loss to economy on account of congestion & poor roads:3 to 6 billion US$62

Unconventional Recycling:Use of Plastics Waste <strong>for</strong> Better RoadsProven on the roads in Madurai & Mumbai63

Unconventional Recycling:Plastics Waste <strong>for</strong> Better Roads –Tar Road laying Road after 7 days Road after 6 monthsAdvantages:• Better binding properties• Withstand Higher temperatures• Withstand Higher loads• Resists permeation of waterBenefits:• @ 10% bitumen replacement• 1 km of 7ft wide road – 1MT of plasticwaste• Av. Savings of 8,000 Rs/kmEven if 10% rural roads covered ~ 2.6 lacs kmSavings of ~ Rs. 2 billion64

Unconventional Recycling:Co-mingled Waste• Recycling of co-mingled waste into(lumber) – a wood substitute• Used <strong>for</strong> landscaping products• Rot proof, water proof, long lastingHelps Conserve Trees65

Conventional Recycling66

Employment in Plastic RecyclingTurnover: > Rs. 15,000 Cr.Volume Recycled:2.6 MMTNo. of Units: ~ 10,000 (mostly small)Total Employment: > 3.5 MillionRag pickers Employed: > 1.5 MillionCreating Employment & Business opportunities67

Plastics Waste <strong>for</strong> Shelter <strong>for</strong> PoorWasteDistributionHappy consumerBarsati FilmMilk PouchDelivering value at every stage68

Plastics Waste <strong>for</strong> Quality of lifeBasketsBagsPlastic Carry BagsMatsValue added aesthetic products – <strong>for</strong> the masses69

RIL Partnership70

Role of Business Development Group• Evolution of concept• Explore / Identify new market• Identify Modern technology• Identify Entrepreneur / Investor• Downstream development• Nurturing new application / Promotion / Marketextension• Securing Approvals From Testing Agencies & Enduser• Regulations / Mandation <strong>for</strong> driving Growth71

A Vital link amongstM/c Mfg. - Converter - End UserMachineryManufacturersExtensive support from• PAT – technical supportBD• Nodal Agencies• Govt. Agencies – <strong>for</strong> Spec- inEnd UsersProcessorsConcept to Commercialization72

Society, Research & Chemical IndustryResearch,is <strong>for</strong> the Benefit of SocietyEven when pursuing very basicresearch,a connection to industry is essential.Without chemistry - no living !Prof. Richard ErnstNobel LaureateWithout chemical industry - no outliving !74

THANK YOU75

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