Jun. 10, 2024
Overview: Since the mid-twentieth century, the volume of packaging in global supply chains has consistently increased. For instance, in the United States, the annual production of packaging and containers grew from 27.4 million tonnes to 67.4 million tonnes over this period.
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One response to this challenge is recycling; however, recycling rates vary significantly across packaging materials. For example, as of recent statistics, the UK recorded a recycling rate of approximately 71 percent for paper and cardboard packaging, in stark contrast to a mere 44 percent for plastic packaging.
In a bid to address these issues, the French company LivingPackets has introduced a groundbreaking concept: reusable packaging designed to reduce waste while enhancing security and efficiency in supply chains and internal logistics.
LivingPackets has developed three innovative products: The Box, The Box Pro, and The Tablet. The Box is a versatile packaging solution crafted from recyclable plastic, eliminating the need for paper, cardboard, polystyrene, or plastic chips. A shape memory mat and cushioning plates allow it to adjust to various product shapes. Furthermore, The Box can conveniently be compressed from a 32-litre container to a flat 2-litre unit when storage requirements demand it.
The Box Pro offers comparable features but is constructed from expanded polypropylene material, providing enhanced waterproofing and exceptional thermal insulation, while also incorporating advanced shock-absorbing technology.
Both The Box and The Box Pro are equipped with a secure locking system to safeguard the goods being shipped. Moreover, they come with an array of sensors that monitor temperature, shock, humidity, and pressure, along with camera functionality and payment technologies. An accompanying app allows for near real-time tracking of the boxes.
The Tablet, a third device featuring a proprietary zero-power screen for displaying electronic labels, can be attached to existing containers, bestowing traditional packaging with the same smart capabilities.
Modernizing outdated packaging systems is crucial for enhancing a company’s operations and bolstering its sustainability credentials. Additionally, our archive reveals an automated approach to reusable containers alongside a comprehensive strategy to assist businesses in transitioning to sustainable packaging solutions.
Written By: Matthew Hempstead
Given its numerous economic and environmental benefits, lightweight packaging has emerged as a trend in the packaging sector.
As the importance of packaging in logistics becomes increasingly recognized, businesses are placing greater emphasis on their packaging choices. It’s critical to note that packaging not only serves as a key factor in the protection of goods but also plays a significant role in transportation and storage expenses, among other logistics processes.
The objective is clear: achieving efficient packaging that safeguards products while remaining economically viable and environmentally mindful.
In the face of these demands, lightweight packaging offers a valuable solution that addresses many of the challenges encountered in supply chains.
Continue reading to discover how opting for the right lightweight packaging can influence a company’s logistics and positively affect its costs and sustainability.
Logistics and packaging: Why is it essential to enhance protective packaging?
For many years, both practical experience and academic research have underscored the pivotal role that packaging solutions play. Packaging is viewed as an interface between the supply chain and its primary customers (the end-users), profoundly impacting supply chain effectiveness (Klevås).
Therefore, optimizing protective packaging is a crucial task that must effectively balance cost-effectiveness, protection, and, increasingly, sustainability.
Achieving the ideal mix of these elements (optimizing packaging) can significantly impact a business's entire supply chain, addressing several challenges such as:
Managing distribution times and preventing delays, which is particularly vital in an era where consumers expect immediate, on-time deliveries.
What is
lightweight packaging?
Lightweight packaging refers to packaging solutions that offer a lighter alternative compared to other options without forfeiting product protection.
Typically, lightweight packaging results from a packaging optimization process aimed at creating a lighter, more efficient solution than the previous version a company employed.
By implementing various strategies, such as using lightweight packaging materials, companies can significantly decrease their packaging weight.
The subsequent advantages include increased efficiency and reduced environmental impact, which we will elaborate on throughout this article.
Lightweight packaging material
options
Achieving lightweight packaging can be facilitated through several strategies.
Typically, reducing the amount of packaging materials is one of the primary actions taken. However, this decision should be made by professionals considering all factors influencing a packaging solution to safeguard product protection and durability.
Ultimately, the selection of materials is crucial in attaining lightweight packaging that does not compromise safety or efficiency.
In this context, EPP and EPS are noteworthy lightweight packaging materials: composed of 98% air and 2% matter, they present a 62% weight reduction compared to other plastics, along with an 82% weight reduction compared to wood.
Additionally, they showcase compelling attributes for packaging, including excellent shock absorption capabilities and thermal insulation, which are vital for packaging solutions related to food or pharmaceuticals, among others.
How does
lightweight packaging material
contribute to logistics?
Cost Savings
Simply put, lighter packaging translates to reduced costs for companies.
Shipping companies calculate costs by assessing the relationship between cargo weight and volume. Consequently, lightweight packaging significantly decreases transportation expenses.
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Moreover, choosing lighter packaging solutions leads to lower energy consumption during transportation and reduces costs related to material acquisition. Collectively, these operations result in diminished overall expenditures.
However, companies must ensure they optimize packaging weight while retaining its protective qualities. This approach will help prevent costly damages and return costs stemming from customer rejections of damaged goods.
Enhancing Efficiency
Lightweight packaging significantly influences supply chains and their efficiency for several reasons:
They increase the amount of full loads companies can achieve while simultaneously reducing packaging expenses. In fact, appropriate lightweight packaging solutions can enhance the number of appliances per pallet by 16%, all while packaging weight decreases by 20%. In other words, lightweight packaging allows for a more efficient use of cargo units.
How does lightweight packaging contribute to sustainable transport logistics?
In recent years, both governmental initiatives and societal demands have prompted companies to reassess their packaging approaches and intensify efforts to mitigate the negative environmental impacts associated with their packaging.
Various strategies exist for achieving sustainable packaging, guided by a commitment to eco-design processes.
Lightweight packaging and the appropriate selection of lightweight packaging materials emerge as key tactics for attaining sustainable packaging.
The following are the outcomes of optimizing packaging to minimize its weight:
A lighter packaging solution necessitates less energy consumption during transportation.
The reduction in carbon footprint may be further enhanced by selecting suitable packaging materials. For instance, EPP and EPS solutions offer a reduced carbon footprint during their production process, thereby lowering a company’s emissions.
Minimize Material Usage
By employing lightweight packaging solutions that utilize fewer materials, businesses create less waste and require less energy.
EPP and EPS materials, composed of 98% air and 2% plastic, provide a sustainable option.
Select Mono-materials
The complexity of recycling processes must also be factored in when evaluating how eco-friendly a packaging solution is.
Packaging made from a single material (termed as ‘mono-materials’) is easier to recycle; these materials undergo less energy-intensive recycling procedures, eliminating the need for prior material separation.
Boost Capacity While Reducing Weight
The logistical advantages provided by lightweight packaging, as outlined above, also yield sustainable benefits.
Ultimately, achieving lightweight packaging remains a critical strategy for ensuring both the efficiency and sustainability of a company’s supply chain.
However, securing an eco-friendly packaging solution must be approached holistically to guarantee product safety is preserved.
Interested in learning more about EPS and EPP and how they can facilitate lightweight packaging while improving a company’s logistics? Download our complimentary technical guide on expanded foam in industry and explore what these materials can offer.
Discussion with Adeline Marchal
Concerning this article on how lightweight packaging can revolutionize your logistics, we spoke with Adeline Marchal, Circular Economy Engineer at Knauf Industries, to gather insights regarding mono-material packaging.
Is mono-material packaging a sustainable long-term solution?
Yes, mono-material solutions facilitate easier sorting in industrial recycling lines.
What is the environmental impact of mono-materials?
Though plastics are derived from fossil resources and are not eco-friendly, they can optimize size and weight, leading to better packaging.
How does mono-material packaging compare to multi-plastic packaging in versatility?
In certain cases, multi-material options enhance packaging functionality, including features like barrier films or electronic devices.
How limiting are mono-materials in terms of functionality, mechanical properties, and design?
This is dependent on the application rather than solely the material itself.
How does Knauf Appliances approach the manufacturing of mono-material packaging?
Knauf Appliances considers specifications, optimizing and adapting designs according to the mechanical requirements of the raw materials.
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