australian packagingreal examples of change & innovation

Fourth Edition 2010

past, present & future

www.pca.org.au

PCA0880_Change&Innovation_Cover_v5.indd 2 2/02/10 4:51 PM

7australian packaging - real examples of change & innovation

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BioPak supplies a new generation of highly versatile, biodegradable, packaging products including plastic resin, film, adhesives, labels and other related packaging consumables all derived from annually renewable resources.

BackgroundBioNet took two years to develop. Together with a local net extrusion company, BioPak trialled a number of different biopolymer blends until a suitable material was found. The biopolymer was easily extruded using existing equipment and produced a net that met all the functional requirements of traditional extruded net packaging.

BeforeTraditional extruded net packaging.

AfterBioNet is manufactured in Australia from a starch based biopolymer. The material is certified industrial or commercial compostable to European Standard EN13432 which means that it will break down into CO2, water and biomass in a compost facility within 180 days.

BioNet has excellent tensile strength and can be used as an effective replacement for conventional extruded net. It is available in a variety of colours, tube diameters and strand gauges to meet specific customer applications.

Applications include:

- Produce Packaging: Oranges, onions, garlic, etc.

- Seafood Packaging: Crabs and mussels.

- Horticulture: Tree guards and soil binding.

- Industrial: Gas cylinder netting.

BioNetBioPak

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Cadbury specialises in confectionery manufacture and is one of the largest and most recognised brands in Australia and internationally.

BackgroundCadbury’s Fun Filled Freddo was launched into the market in 2006 and became an immediate success in the “preteen” category, gaining wide distribution in grocery and convenience markets. During 2008, the Cadbury packaging team focussed on developing and testing alternative pack formats that would provide protection for the product in the warehouse and distribution systems yet enable a reduction in the amount of packaging required to deliver the product to the point of sale and also increase the distribution efficiency.

BeforePreviously, Fun Filled Freddo was displayed in an E Flute inner with a separate header card, along with two bio-plastic trays for stability. The display unit was further encased in a corrugate container for distribution.

AfterThe Adventure Freddo format replaced Fun Filled Freddo, increasing the unit count from 20 to 24 units. This resulted in a reduction of 18,000kg of packaging for the equivalent volume of units sold in 2008. There was an overall reduction in packaging of 61% and, as a result, a 62% improvement in palletisation, reducing warehouse space and providing transport and energy savings.

All of the packaging items are recyclable through the current kerbside recycling system.

24g Adventure FreddoCadbury

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Carter Holt Harvey Packaging is one of Australasia’s largest fibre packaging manufacturers with nearly 1800 staff, 15 manufacturing facilities and sales offices in New Zealand, Australia and Fiji, and supplies customers in Australasia, Asia, the Pacific and South America.

BackgroundThe new Cadbury Block Chocolate packaging showcases a new sleek, stylish and modern carton, enhanced by gold-stamping and embossed features. The carton is easier to open, and because it is re-sealable, helps the foil maintain freshness of the chocolate inside.

BeforeThe previous Cadbury Block Chocolate packaging with its metallised paper wrap was difficult to recycle, and more likely to be crumpled up as waste by the consumer as it was not perceived as recyclable.

AfterThe new packaging is manufactured from 100% recyclable cartonboard and the mill is accredited to the internationally recognised Forest Stewardship Council. Cadbury’s extensive consumer research identified that 70% of the new packaging is likely to be recycled as it is easily identified as cardboard waste. The new pack also offers exceptional product protection, is re-closable and even serves as a handy tray for sharing. In addition, the supply chain for the cartonboard is shorter (from New Zealand rather than USA) with resultant emission reductions.

Cadbury Block Chocolate Range 100gm & 200gm

Carter Holt Harvey ‘The Solution Centre’

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Cryovac Australia is a manufacturer of materials and systems for protective and fresh food packaging in the industrial and fast moving consumer goods (FMCG) markets.

BackgroundAuthentico Pasta Sauce is a new product for the Leggo’s brand owner, Simplot Australia. It is specifically designed for simplicity and safety of use in the microwaveable category.

BeforeAlternate pack formats in the microwaveable category generally rely on thick-walls, 0.7 – 0.8 mm for insulation and rigidity when hot. Also, alternate packs are either direct printed, or have PVC or PS based shrink-sleeves applied to provide insulation. As a result, the inks and/or sleeves cannot be easily removed from the base container for recycling and end up in landfill.

AfterCryovac’s fibreboard sleeved Combi Cup uses a thin polypropylene (PP) wall section which is only 0.55mm thick and therefore is around 30% thinner than many alternative microwaveable containers. It has a mechanically applied (no glue is used) cardboard sleeve which offers excellent insulation and rigidity for safe handling when hot. The lid incorporates vent holes to allow steam to escape during heating. When the consumer has finished preparing this meal solution, the container’s components (PP and paper) are easily separated to aid recycling and are accepted by council kerbside collection.

Leggo’s Authentico Fresh Pasta SauceCryovac Australia

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AfterBefore

KeepCup have created the world’s first barista standard reusable cups. Locally designed and manufactured, KeepCup seeks to transform the way Australians and citizens of the world enjoy their take away coffee.

BackgroundLaunched in June 2009, KeepCups have been created to reduce our consumption of disposable cups.

BeforePreviously there were no alternatives that replicated the internal volumes of disposable cups (enabling correct and consistent proportioning of espresso and milk) or that fitted under the machine group heads.

AfterKeepCups are a new innovation manufactured from single component recyclable materials – polypropylene, silicone and TPU and are available in the three standard sizes. The KeepCup is reusable, splashproof, dishwasher and microwave safe, and stackable for transportation. They are non-toxic, Bisphenol A (BPA) free and come in a range of colours. They have an estimated lifespan of four years.

KeepCup

15australian packaging - real examples of change & innovation

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Nicholson Fine Foods produces high quality food products that are used in Australia and exported currently to Hong Kong and soon to the United States.

BackgroundBio Burger is an all natural dry burger blend that takes a holistic, full cycle approach to the product and its packaging.

BeforePreviously, products in this category were packaged in paper based boxes or laminated plastic pouches.

AfterThe Bio Burger has reinvigorated this category. The primary packaging is made from Euro standard “certified compostable” bamboo and the outer packaging is made of 100% recycled paper stock. An efficient product design has minimised packaging material waste, with off cut wastage accounting for only 3%.

Each step along the Bio Buger’s production has been carefully considered in terms of the economic, social and environmental impact. Manufacturing takes place in a factory that buys 100% renewable Green Power, which has reduced carbon dioxide waste into the atmosphere by 100%. The product also requires very low energy consumption as it doesn’t require refrigeration during manufacturing and storage.

Bio Burger ‘Whole food whole life’Nicholson Fine Foods