Creating A More Sustainable Gallon Jug For Milk Dr Gail Barnes, Partner, Personify LLC

International Dairy Show

Monday, November 4, 2013 - 12:30PM - 12:50PM

Booth 1074 - iDairyShow Theater

Chicago, IL

Summary • 85% of fluid milk in the USA is packaged in monolayer HDPE packaging,

with the result that any reduction in the amount of plastic used can have a major impact on reducing the carbon footprint.

• This presentation will discuss the results of studies of a progression of ways in which the amount of plastic used in the creation of gallon jugs can be reduced. – Light-weighting through container design. – Adding calcium carbonate as a filler. – Light-Weighting + optimizing for calcium carbonate filler.

• These results meet recommendations coming out of the Life Cycle Analysis study conducted by the Innovation Center for US Dairy which recommended light-weighting or container weight reduction as a key focus area for improvement in the supply chain impact of fluid milk.

• A recipe for the gallon jug of the future will be presented, and the hypothesis made that “Integrated Design” will be the next frontier in creating a more sustainable gallon jug for milk.

Packaging Principles

• Packaging should: – Be fit for purpose.

– Be the lightest weight possible.

– Use materials from the most sustainable sources.

– Maximize opportunities for recovery and recycling.

– Be designed to have the lowest carbon impact.

– Be aesthetically pleasing and convenient to use.

U.S. Fluid Milk Infographic

Source: Principles of a measurement framework: application to processing and packaging technologies. Institute of Food Technologists Annual Meeting and Food Expo, Las Vegas, NV, June 27, 2012

U.S. Fluid Milk Carbon Footprint

Processing & Packaging LCA

• Comprehensive LCA of fluid milk delivery systems in the U.S.

• Assessment of environmental impacts of 18 fluid milk packaging and delivery options.

Source: Principles of a measurement framework: application to processing and packaging technologies. Institute of Food Technologists Annual Meeting and Food Expo, Las Vegas, NV, June 27, 2012

Fluid Milk Delivery Systems Studied

Source: Principles of a measurement framework: application to processing and packaging technologies. Institute of Food Technologists Annual Meeting and Food Expo, Las Vegas, NV, June 27, 2012

Climate Change Impact Assessment

Source: Principles of a measurement framework: application to processing and packaging technologies. Institute of Food Technologists Annual Meeting and Food Expo, Las Vegas, NV, June 27, 2012

Non-Renewable Fossil Energy Assessment

Source: Principles of a measurement framework: application to processing and packaging technologies. Institute of Food Technologists Annual Meeting and Food Expo, Las Vegas, NV, June 27, 2012

Processing & Packaging LCA Conclusion

• Differences between systems are relatively small.

• Comparative assertions of performance are not supported.

• Differences between systems are largely defined by container material and mass.

Source: Comprehensive life cycle assessment of fluid milk delivery systems, 8th International Conference on Life Cycle Assessment in the Agri-Food sector, Saint-Malo, France, Oct. 1-4, 2012

Recommendations For Improvement In Supply Chain Impact

• Container – Container weight reduction, especially in on-the-go systems. – Improved use of distribution packaging that can be used many times. – Reduce energy use which improves multiple impact category effects.

• Processing plant – Energy efficiency would directly lower impact to climate change and

costs. – Water use and wastewater reduction in processing plant which will

affect eutrophication mitigation, and cost reduction. – Avoid sewage overload which is the main contributor to nitrogen

emission to water and cause of eutrophication. – Evaluate wastewater treatment discharges for potential reduction in

human toxicity, and eco toxicity, cost savings. – Optimize out-of-date (from distribution and retail center) milk return

and use as feed.

Source: Principles of a measurement framework: application to processing and packaging technologies. Institute of Food Technologists Annual Meeting and Food Expo, Las Vegas, NV, June 27, 2012

Study 1: Light-Weighting Through Container Design

12% weight savings through optimized design alone

Source: Uniloy

Study 2: Adding Calcium Carbonate As A Filler

Source: Uniloy and Omya

• Recycling recovery rate of 99% with CaCO3 levels up to 8%.

• CaCO3 compounded in a master batch, doesn't require changes to equipment except for the addition of a material blender.

Study 3: Light-Weighting + Optimizing For Calcium Carbonate Filler

• Required optimizing design to regain top load e.g.

– Tucked in handle.

– Ribs on bottom and shoulder.

• 54g bottle possible.

Source: Uniloy

Future Possibilities – Adding Recycled Content

• Arla UK’s bottles already made of 15% rHDPE.

• Bottles made with 50% post-consumer recycled content will be produced at Arla's new Aylesbury dairy.

Source: Arla Foods, Plastics Today

Future Possibilities – Using Bio-Resins

• Bio-plastics are plastics made using ethanol from renewable resources such as sugarcane and corn or crop waste.

• Any grade of HDPE or LDPE can be made using the biopolymer.

• Up to 30% bio-resin content envisaged.

Recipe For Tomorrow’s Gallon Jug?

• For a 56g gallon jug: – 29.7g virgin HDPE

reduces the amount of virgin HDPE by more than 50%!

– 16.8 grams biopolymer.

– 5.6 grams rHDPE. – 3.9 grams calcium

carbonate.

Today’s gallon jug

“Integrated Design” Is The Next Frontier

• Using the minimum input and getting maximum use of materials at the end.

• Can only come about by the value chain working together: – Raw materials suppliers. – Equipment manufacturers, e.g. of blow molding

equipment. – Distribution equipment manufacturers, e.g. of crate

packing equipment. – Processors/brand owners. – Retailers.

Thank You

www.linkedin.com/in/gailbarnes

@DrGailB