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1

PET & other Plastic

Containers:

Industry Overview and Innovative Solutions for

Food Packaging

ILSIILSIILSIILSI----INDIA CONFERENCE ONINDIA CONFERENCE ONINDIA CONFERENCE ONINDIA CONFERENCE ON

FOOD SAFETY AND SECURITYFOOD SAFETY AND SECURITYFOOD SAFETY AND SECURITYFOOD SAFETY AND SECURITY

New Delhi 27-28 February, 2017

Dr. Vijay G. HabbuSenior VP-Reliance Ind. Ltd.

Technical Advisor- PCMA, PACE

Section 1 : Basics of

Packaging

LAYING THE FOUNDATION ON PACKAGING 2

Packaging is an inevitable part of our lives.e.g. food items, pharmaceuticals, electronic goods, books, clothes, letters.

Packaging is needed to fulfil several objectives:

1. Shelf life, i.e. to maintain the organoleptic properties over a long period

2. Preservation – prevent temperature fluctuations, bacterial ingress, dust, etc.

3. Barrier protection – prevent migration of oxygen, water vapor, UV light, etc.

4. Physical protection - from shock, vibration, compression, etc.

5. Security – prevent pilferage and/or tampering. Also for assuring authenticity.

6. Containment or agglomeration - Liquids, powders and granular materials need containment for efficient handling.

Purpose of Packaging-1

3

7. Portion control - Single-serving packaging has a precise amount of contents to control usage.

8. Information transmission - Packages and labels communicate how to use, transport, recycle, or dispose of the package or product. Some types of information are required by governments.

9. Traceability – As per Codex Alimentarius Commission 2004 (Codex), traceability has 3 objectives: - to improve supply management- to facilitate trace-back for food safety & quality purposes, and - to differentiate and market foods with subtle or undetectable quality attributes.

10. Convenience - Packages can have features which add convenience in distribution, handling, stacking, display, sale, opening, reclosing, use, and reuse.

11. Marketing - The packaging and labels can be used by marketers to encourage potential buyers to purchase the product.

Purpose of Packaging-2

4Packaging essential for preservation, dispensation and information

Packaging materials : the gamut

Global segment breakup of packaging materials (%)

5All packaging materials are SYNTHETIC &/or need external processing

Did you

know?

Producing a plastic bag

consumes only

3%of the

fresh water needed to produce a paper bag

Trends in Packaging – Plastics (1)

Plastics are increasingly replacing traditional materials

7Even glass, metal and paper containers need to have plastics in their closures or COATING of polymers !!!

Evolution is Natural, Inevitable and Irreversible


8

• Packaging is one of the fastest growing industries ~ USD 700 billion GLOBALLY.

• Indian packaging industry

• ~4% of global

• expected growth rate 18% p.a. (flexible packaging @ 25 % p.a. & rigid packaging @ 15 % p.a.)


9

Plastic Packaging Industry Outlook (USD Bn)

Plastic packaging poised for significant growth in India

Packaging Mix across Categories/Countries

64% 64% 59% 52% 55%

USA Europe China Brazil India

73% 74%83% 85% 83%


Personal Care Home Care

60% 63% 71% 77%59%


Beverages

Plastics Non- Plastics

Source: FICCI Report

62% 66% 69% 70%83%


Packaged Food

10Plastics are the preferred packaging material for consumer goods

Plastics- Food Packaging Materials in India

Source: FICCI Report

11

Plastics Non- Plastics

Plastics are the preferred packaging material for most food items

98% 98%93% 93%

82%75%

54%49%

Biscuits Dried Processed Baked Goods Dairy Oils & Fat Confectionery Carbonated Baby Food

Section 2 :

Plastics in Packaging:

An Industry Overview

PLASTICS IN FOOD PACKAGING: A BIRD’S EYE VIEW 12

1284 1913

First recorded mention of The Horners

Company of London, with horn and

tortoiseshell as the predominant early

natural plastic.

First recorded mention of The Horners

Company of London, with horn and

tortoiseshell as the predominant early

natural plastic.

Friedrich Heinrich

August Klatte

(GERMAN) took out a

patent on PVC

Friedrich Heinrich

August Klatte

(GERMAN) took out a

patent on PVC

1933

Polyethylene

discovered

Polyethylene

discovered

1935

Nylon

patented

Nylon

patented

1937

First commercial

production of

polystyrene

First commercial

production of

polystyrene

First production

of PVC in UK

First production

of PVC in UK

1940

1941

1948

1950

PET

patented

PET

patented

Acrylonitrile-

butadiene-styrene

(ABS) produced

Acrylonitrile-

butadiene-styrene

(ABS) produced

The polyethylene

bag makes its first

appearance

The polyethylene

bag makes its first

appearance

PP inventedPP invented

HDPE

invented

HDPE

invented

First production of

polycarbonates

First production of

polycarbonates

PET beverage

bottles

introduced

PET beverage

bottles

introduced

First

production of

LLDPE

First

production of

LLDPE

First artificial

heart made

mainly of

polyurethane,

introduced

implanted in a

human.

First artificial

heart made

mainly of

polyurethane,

introduced

implanted in a

human.

1952 1958 1980

1953 1973 1982

Inventions of Plastics : Timeline

Bakelite

manufactured

Bakelite

manufactured

1907

13Fascinating evolution of synthetic plastics over the past 110 years

PolymerizationPolymer Manufacturers

Polymer/Resin

Injection Moulding

Blow Moulding

Roto Moulding

Colorants AdditivesPlastics/Articles

• Extrusion

• Casting

• Moulding

Convertors

Catalyst

Petrochemical RefinersMonomers• Globally, 20

• 5 in India

• 6 for all plastics (in India)

• 3 for PET (in India)

• 50,000 for all plastics (in India)

• 1500 for PET (in India)

Plastics Formation Process

Very Large Scale

Large Scale

Small Scale

14Converting plastic resins into shaped articles is very simple and gentle

• Originally developed by the Society of the Plastics Industry (now PLASTICS) in 1988, but being administered by ASTM International since 2008

• The RIC system was designed to make it easier to sort and separate plastic items according to their resin type

• In its original form, the symbols consisted of arrows that cycle clockwise to form a triangle that enclosed a number

• In the 2013 revision to the RIC, the ‘chasing arrows’ have been replaced with a solid triangle, in order to address consumer confusion about the meaning of the RIC

However, in India

IS 14534 (1998) : HAS RETAINED THE TRIANGLES WITH CHASING ARROWS

Resin Identification Codes for Plastics

15Codes help the consumer identify the type of plastic

Plastic

Identification

Code

Name of the plastic

(Polymer)

Constituents of the plastic

(Monomers)

Typical End Uses

(Food & Non-Food)

Polyethylene terephthalate

(PET, PETE)

Terephthalic acid + isophthalic acid +

Ethylene glycol (or MEG)

Bottles, Containers, Jars, Films, Strappings, Fibre and

Filaments, Non-wovens, Medical devices, etc.

High-density polyethylene (HDPE) Ethylene Hair-oil & other household containers, Packaging films,

furniture, Pipes, Fuel tanks, etc.

Polyvinyl chloride (PVC) Vinyl Chloride monomer (VCM) Wire and cables, Footwear, Floorings, Packaging films,

Pipes and fittings, Medical devices, Tarpaulins, toys, etc.

Low-density polyethylene (LDPE) Ethylene Milk pouches, Containers, packaging films, tubings,

Furniture, etc.

Polypropylene (PP) Propylene Chairs, Furniture, Containers, Packaging films,

Automotive and Electronic components, Textiles,

Medical devices, Aerospace Applications, etc.

Polystyrene (PS) Styrene Protective packaging applications, Disposable cups and

containers, Foams, Insulations, etc.

Other plastics

[often Polycarbonate (PC) or

Acrylonitrile butadiene styrene

(ABS)]

PC: Bisphenol-A + Diphenyl carbonate or

Phosgene

ABS: acrylonitrile + butadiene + styrene

PC: Electronic, Aircraft, Security and Automotive

components, Construction industries, Data Storage

applications

ABS: Electronic and Automotive components, Pipes,

Instruments body parts, etc.

Plastics: Codes, Chemistry and End-uses

Each plastic has a different chemistry16

Plastics: Benefits of each Resin

17Each plastic has a unique set of advantages

Polymers Market:

205 MMT (2016)

#1 Polyethylene Terephthalate: 16.4 MMT

#2 High Density Polyethylene: 34.85 MMT

#3 Polyvinyl Chloride: 36.9 MMT

#4 Low Density Polyethylene: 18.45 MMT

#5 Polypropylene: 56.1 MMT

#6 Polystyrene: 10.25 MMT

Plastics: Global Production

18

The per capita consumption of polymers in India during 2014-15 was just 10.5 kg

as compared to 109 kg in USA, 45 kg in China and 32 kg in Brazil

PP, 53.3

PVC, 36.9

HDPE, 34.85

LDPE, 18.45

PET, 16.4

PS, 10.25

Others, 34.85

GLOBAL PRODUCTION CAPACITY (MMT)

Good products yet a victim of malicious propaganda:

The PET Story19

1. Heavy metals

• PET does not need As, Cd, Cr, Hg, Pb at any stage of its manufacture.

• In fact, the presence of these heavy metals is counterproductive (haze)

• Hence, they are not used

2. Antimony (catalyst)

a) In the polymer (under normal usage conditions):

It is fixed in the polymer (just like dyes). Remember, PET is the samepolyester of which garments are made

b) Migration at high temperatures:

Modelling studies even at 150°C prove that leaching of antimony isbelow European permissible limits (40ppb)

The above hazards are WRONGLY attributed to PET

Recently raised Concerns about PET Packaging

20

Welle, F and Franz R

Food Addit Contam Part A Chem Anal Control Expo Risk Assess.

2011 Jan; 28(1):115-26.

doi: 10.1080/19440049.2010.530296.

3. DEHP and other Phthalates

• Either as plasticizers or additives, these chemicals are not needed nor generated, hence not present in PET

• Other than similarity in their names, phthalates and polyethylene terephthalate have nothing in common

4. Colorants

• Colored PET bottles are made using food colorants • Conforming to following regulations* on colorants for

food contact materials:� US Federal Food, Drug, and Cosmetic Act,

� Council of Europe (CoE) Resolution AP (89) 1 � EU regulation 10/2011BIS 9833

*Pigments and Colorants in plastics for contact with Foodstuffs, Pharma & Drinking water


21

Phthalates

Polyethylene

terephthalate


5. Bisphenol-A (BPA)

• Bisphenol-A is a constituent of Polycarbonate, a different plastic than PET

• PET is necessarily BPA-free

6. Oestrogenic reactivity

• Endocrine Disrupting chemicals (EDCs) are not used nor generated in PET

• US-EPA’s EDC screening programme does not even list PET/plastics

7. PET (amber PET) is not recyclable

• All PET bottles/containers are recycled into high-premium products (garments/upholstery/furnishings)

• Amber PET is used to make black colored textiles



22

PET : simple and safe chemistry

PET does NOT contain :

• Heavy metals (like As, Cd, Cr, Hg, Pb)

• Phthalates (e.g. DEHP)

• Bisphenol-A

23

PET resins comply with Specific Migration Limit as per

• BIS: 12252-1987 (2005)

• US FDA 21 CFR §177.1630

• Regulation (EU) 10/2011

on plastic materials and articles intended to come into contact with food

PET does not contain any hazardous chemicals –

• Hence PET is not carcinogenic to humans in any way

• recommended by WHO and other international regulatory bodies

• as safe packaging material

Hazard and risk

� A dangerous animal can be seen as

a „Hazard“.

source : Dr. U. Wolfmeier, Clariant

Hazard x Dose (Exposure) = Risk

Be careful, but know the facts

� However when the animal is closed

in a cage, it remains „hazardous“ but there is no exposure to it,…

� When the animal is free, people in

its surroundings are exposed to it.

� Consequently, there is a Risk that these people might be attacked

� .... consequently there is no risk

Allowable Limits of Some Hazardous Migrant Chemicals

PET does not contain hazardous substances nor do any leachants cross the allowable limits

BIS

IS 10500:2012

BIS

IS 13428:2005

FSSAI

Regulation 2011

Drinking water

Packaged

Natural Mineral

Water

Food Safety & Standards

(Contaminants, Toxins &

Residues)

PHTHALATES

Water 8.0 µg/L 6.0 µg/L

Food SML < 1.5 mg/kg

Water

Food SML < 30 mg/kg

Water


Water

Food SML(T) < 32 mg/kg

ORGANICS

Water


HEAVY METALS

<5.0 µg/L Water No Limits 5.0 µg/L 20.0 µg/L 5.0 µg/L 6.0 µg/L 6.0 µg/L

SML < 0.04 mg/kg Food SML < 0.04 mg/kg

Water 10.0 µg/L 50.0 µg/L 10.0 µg/L 10.0 µg/L

Food0.1 mg/kg (Milk)

0.05 mg/kg (Infant Milk & foods)

Water 3.0 µg/L 3.0 µg/L 3.0 µg/L 5.0 µg/L 5.0 µg/L

Food 0.1 mg/kg (Infant Milk & foods)

Water 50.0 µg/L 50.0 µg/L 50.0 µg/L 100 µg/L 50.0 µg/L

Food 0.02 mg/kg (Refined sugar) 1.0 mg/kg in Plastic

Water 10.0 µg/L 10.0 µg/L 10.0 µg/L 15.0 µg/L 10.0 µg/L

Beverages 0.5 mg/kg (Beverages)

Food 0.2 mg/kg (Infant Milk & foods) 2.0 mg/kg in Plastic

Water 1.0 µg/L 1.0 µg/L 6.0 µg/L 1.0 µg/L

Food 0.25 mg/kg (All foods)

SML = Specific Migration Limit

Limits

WHOEU Regulation

10/2011US EPA

Health

Canada

Sr.

No.

Migrant Chemical

(leachate)CAS No

Max possible

conc. in

PET/leaching

from PET

Leachate

destination

(Contents

of the PET

container)

3 Diisononyl phthalate (DINP)

14103-61-8,

20548-62-3

28553-12-0,

68515-48-0

Not Used

1Di(2-ethylhexyl) phthalate i.e.

Dioctyl phthalate (DEHP/DOP)117-81-7 Not Used

2 Benzyl butyl phthalate (BBP) 85-68-7 Not Used

Not Used

5 Acetaldehyde 75-07-0 < 6.0 mg/kg

6 Antimony 7440-36-0

4 Total of all Phthalates

11 Mercury 7439-97-6 Not Used

9 Chromium 7440-47-3 Not Used

10 Lead 7439-92-1 Not Used

7 Arsenic 7440-38-2 Not Used

8 Cadmium 7440-43-9 Not Used

PET – safety markers

• No leaching above any permissible limits

• Eminently recycled into useful non-bottle applications

• Bottles made from Recycled PET not allowed for packaging pharma & food – hence no room for mistakes

• Cattle or marine life do not eat bottles

• Bottles are easily retrieved

• Bottles are re-used for multiple purposes – lowering the consumption of packaging materials

26Trust the facts not the myths

Section 3 :

Plastics in food packaging: The safety

assurances

INDIA NEEDS TO REMAIN COMPETITIVE BY MAINTAINING BEST INTERNATIONAL PRACTICES 27

HDPE

PS

Advantages of Plastics in Food Packaging

Bio-inertness, resistance to corrosion and

stability under acidic & basic conditions,

make plastics very resource efficient materials for

Food packaging

The wonder material: Plastics 28

PET

PVC

LDPE

PP

Advantages of Plastics in Food Packaging

29

Adaptability: Can be molded into any shape.

Freedom on packaging product

design.

Cost-effectiveness:Plastics do not add much to the

cost of a product.

The transportation costs are low

- up to consumers

- recycling centres

Sustainability:Plastics are commonly &

frequently recycled materials.

Durability:Plastics provide protection over

the entire life cycle of the

contents (products).

Plastics don’t shatter or get torn.

Versatility:Offers endless packaging options

– pouches, bottles, containers,

flow wraps, blisters, films, trays,

shells, drums, ..

Lightweight:Very light compared to other

forms that are 2-8 times heavier.

Thus transportation is less

cumbersome and cost effective.

This combination of virtues not available in any other packaging material

Food Packaging: Per Capita Spend and Industry Trend

Indian Packaged Food Spend (Per capita)

30Growth of plastics for food packaging in sync with the GoI’s plans

Did you

know?

Plastic Films increases a cucumber’s shelf-life by 14

days

29

International Regulations for Food and Pharma packaging

INTERNATIONAL REGULATORY BODIES

• World Health Organisation (WHO):

International Conference on Harmonisation, stability guidelines Q1A-Q1F

• International Standardisation Organisation (ISO):

ISO 22000:2005: Food Safety Management System (FSMS) for ‘Manufacture and dispatch of Polyethylene

Terephthalate (PET) as raw material for food packaging applications’.

UNITED STATES GOVERNMENT

• US FDA (Code of Federal Regulations, CFR Title 21, Section 177.1630)

• US Pharamocopeia (USP, Chapter 661)

EUROPEAN UNION

• European Pharmacopoeia monograph (Sections 3.1.15, 3.2.2.1, 3.2.2)

• European Medicines Agency

JAPAN

• Pharmaceuticals and Medical Devices Agency

International agencies have for long approved PET as a packaging material 32

33

April 2015 Report, Section 35, p. 18

35. What kinds of plastics are used for food

handling and storage and are there any health

hazards of using it?

Plastic packaging plays a signification role in the shelf life

and ease of storage and cooking for many foods and most

are safe to use provided that they are used appropriately.

1. Polyethylene terephthalate (PET) is used to make soft

drink, water, sports drink, ketchup, and salad dressing

bottles, and peanut butter, pickle jelly and jam jars. It

is strong, heat resistant and resistant to gases and

acidic foods. It can be transparent or opaque. Not

known to leach any chemicals that are suspected of

causing cancer or disrupting hormones and it can be

recycled.

2. High density polyethylene (HDPE) ……

3. Low-density polyethylene (LDPE) …..

4. Polypropylene (PP) …..

5. Polycarbonate ……

In addition, polystyrene (PS) and polyvinyl chloride

(PVC) are also used during food material transportation

and handling in supermarkets. Modern food safe plastic

bags are plasticizer-free and will not release harmful

chemicals into your food while it is being cooked.

INTERNATIONAL Reports on PET

WHO

� Food Safety : What you should know (Section 35, p. 18, Apr 2015)

Canadian govt.

� Scientific Review of all studies on DEHP (Nov 2014)

Hanno C. Erythropel et al, Appl Microbiol Biotechnol (2014) 98:9967–9981

Spanish govt.

� Laboratory studies of 110 PET samples (May 2014)

Albert Guart, Francisco Bono-Blay , Antonio Borrell, Silvia Lacorte, Food Chemistry, 156

(2014) 73-80

International LifeSciences Institute (ILSI), Belgium

� PET for Food Packaging Applications (2000)

NAPCOR, USA

� PET Safety

Keller and Heckman, USA

� Opinion letter

All respectable international bodies have endorsed the usage of PET bottles for packaging

based on assessment under conditions harsher than those prevalent in India 34

Pharma packaging : Indian Regulations allow PET

GOVERNMENTAL ACTS

• Indian Drugs and Cosmetics Act (1940), Schedule M, Section 16.10 Stability studies

• Indian Drugs and Cosmetics Rules (1945), Schedule M, para 11 Pharmacopoeial compliance

� FSSA Act (2006) created the Food Safety and Standards Authority of India (FSSAI)

formulates specifications for foods that have common features for Pharmaceuticals

INDIAN PHARMACOPOEIA

• IP 2014, General Chapter 6.2.3 PET containers for packaging of Pharmaceuticals

BUREAU OF INDIAN STANDARDS

• IS 12229-1987 (R2005) : Positive list of Constituents (PET) for their

Safe use in Contact with Foodstuffs, Pharmaceutical and Drinking water

• IS 12252-1987 (R2005) : Specifications for PET for Pharmaceuticals

• IS 9845-1998 : Determination of Overall Migration of constituents of Plastics Materials and Articles intended

to come in contact with Foodstuffs – Method of Analysis

• Several other Indian standards exist to control & allow PET containers for Pharma packing

Indian Govt. has already permitted the use of PET for packaging

35

Plastic Sample Regulations

Polyethylene terephthalate

(PET, PETE)

IS:9845, IS:12229, IS:12252, IS:9833

US FDA: CFR Title 21, Section 177.1630

High-density polyethylene (HDPE)IS:10146, IS:10141


Polyvinyl chloride (PVC)IS:10151, IS:10148

Low-density polyethylene (LDPE)

IS:10146, IS:10141

US FDA: CFR Title21, Section 177.1520

Polypropylene (PP)

IS:10910


Plastics for Food packaging : governing regulations

36

Till date about 1100 Indian Standards on various plastic products and their test methods have

been developed and about 150 are at various stages of development.

Indian Studies on PET Bottles

CFTRI, Mysore

� Global Migration Studies:

� for compliance with US FDA 21 CFR

§177.1630 (2011) < 0.5 mg/in2 and

� for compliance with BIS: 12252-1987

(2005) (Extractable <10 mg/dm2 and <

60 ppm)

ITRC, Lucknow

� Global Migration

� Heavy Metals

� Biological tests

CU Shah College of Pharmacy, Mumbai

� Stability study on a Cough syrup in Plastic

Containers

These actual studies establish that PET is a safe container

Indian Institute of Packaging, Mumbai

� Global Migration

Italab Pvt. Ltd., Mumbai

� Systemic Injection test

� Intracutaneous test

Intertek, Mumbai (Nov 2014)

� Heavy metals

Shriram Institute for Industrial Research, New Delhi

(Nov 2014)

� Heavy metals37

PET : has been around for a long time, the world over

PET is one of the SAFEST materials38

PET fibres

being made for

more than

65 years

PET bottles

• have been made for more than 42 years

• manufactured all over the world

• more than 300 million MT already used globally

• more than 15 trillion bottles packed and consumed

NO EPIDEMIOLOGICALLY ADVERSE OBSERVATION GLOBALLY

• No case reported on any occupational hazards faced by the work-force (inhalation ingress)

• No case of health effects on civilian consumers (oral ingress)

• No case of health effects due to draping garments (dermal ingress)

• Not a single clinical evidence correlating any ailment with PET chemistry

Section 4 :

Sustainable Plastic

Packaging

PLASTICS ARE MOST ENVIRONMENTALLY BENIGN MATERIALS 39

• Recycling of plastics - is a prime area for innovation and sustainability

• In India, ~3500 organized and ~4000 unorganized plastic recycling units.

• Most plastics (PET, PE, PVC, PP, PS) are recycled via mechanical route

• Recycling of plastics ~3.6 MnTPA, provides employment to ~ 1.6 million people

(0.6 million directly, 1 million indirectly)

Recycling of Plastic Packaging : the India story

Sustainability Best Practices

40Paving our way towards a ‘Cleaner and Greener’ nation

Post-Consumer Waste & Collection

Municipal Solid Waste Segregation

Municipal Solid Waste – Indian cities

60,000 MT/day in 300 class I cities

• Wet compostable waste 38%

• Inert waste 49%

• Paper & Paperboard waste 6%

• Plastics waste 4%

Municipal Solid Waste – Indian cities

60,000 MT/day in 300 class I cities

• Wet compostable waste 38%

• Inert waste 49%

• Paper & Paperboard waste 6%

• Plastics waste 4%

Recycling of Plastic Packaging

41Contrary to uniformed perception, plastics constitute the lowest litter

PET – Sustainable Solutions for Waste Management (1)

Recycled Polyester Fibre (r-PSF)

Recycled Yarn r- PET T-shirtPET bottle scrap

Value chain for PET recycling already exists and country has enough capacity for recycling of PET

42PET gets converted into polyester textiles - a sterling ambassador of the circular economy

43

PET – Sustainable Solutions for Waste Management (2)

Environmental care: Institutionalised by the PET industry > 70% PET is recycled

• Plastics are now emerging as a sustainable and a smarter choice for food packaging

• Using alternatives of plastic packaging can result an increase in packaging weight, energy consumption and global warming

Sustainable Packaging : Advantage Plastics

44Plastics provide best sustainability interventions in the packaging value chain

Cost of Packaging

Energy Consumption

Volume of Waste

Weight of Packaging

Paper & Paperboard

Glass

Metal

Sustainable Packaging: Resource Conservation

45Plastics are most friendly to the environment and to the consumers

AVERAGE VALUES

(of data cited earlier)Weight of container

needed for packing

300mL of liquid

EFFECTIVE VALUES

Of

Packaging Material

Emissions E.F. Emissions E.F.

kgCO2/T Gha/T gFactor

(w.r.t. PET)kgCO2/T (Gha/T)

Glass 990 0.24 162 6x 5940 1.44

Aluminium 10840 2.42 15 0.6x 6504 1.45

PET 2240 0.48 24 1x 2240 0.48

Normalisation taking into account

the weight of packing material needed for packing same amount of contents

Normalised Data – GHG Emissions & Ecological Footprints (E.F.)

[1] Accounting for Greenhouse Gas Emissions of Materials at the Urban Scale- Relating Existing Process Life Cycle Assessment Studies to

Urban Material and Waste Composition, Meidad Kissinger et al., Scientific Research, Low Carbon Economy, 2013, 4, 36-44[2] Accounting for the Ecological Footprint of Materials in Consumer Goods at the Urban Scale,

Meidad Kissinger et al., Sustainability 2013, 5, 1960-1973; doi:10.3390/su5051960

Gha/T = Giga hectares/ ton of

packaging material

46

Reduce

Recycle

ReuseRecover

Let us Learn the “4Rs” in Plastics Usage …

Sustainability also needs to be seen as serving the aims of INCLUSIVE GROWTH

Section 5 :

PET : Innovations

PET/PLASTICS: MOST AMENABLE TO INNOVATIONS FOR THE PACKAGING INDUSTRY48

Use of Plastics

Plastics are materials

made of any of a wide

range of synthetic or

Semi-synthetic organics

that can be molded into

solid objects of diverse

shapes

Plastics

Packaging

Building

&

Construction

Transportation

Electrical

&

Electronics

Medical

&

Health

Agriculture

Sports

&

Leisure

Plastics cover every aspect of your daily life 49

Manifestations of Polymers

1. Plastics

2. Fibres (Textiles)

3. Rubbers / Elastomers

50

4. Coatings

5. Adhesives

6. Cosmetics

Nobel Laureates in Polymer Science

Hermann StaudingerMar 23, 1881-Sep 8, 1965For contributions to the understanding of macromolecular chemistry

Giulio Natta

Feb 26, 1903- May 2 1979

For contributions in polymer synthesis (Ziegler-Natta catalysis).

Paul John Flory

Jun 19, 1910- Sep 9, 1985

For contributions to theoretical polymer chemistry

Pierre-Gilles de Gennes

Oct 24, 1932- May 18, 2007

For describing ordering and phase transitions in polymers.

Alan G. MacDiarmid

Apr 14, 1927- Feb 7, 2007

For work on

conductive polymers

Koichi Tanaka

Aug 3, 1959-

For biological macromolecules

Robert H. Grubbs

Feb 27, 1942-

For olefin metathesis

Karl Waldemar ZieglerNov 26, 1898- Aug 12, 1973

For contributions in polymer

synthesis (Ziegler-Natta catalysis).

Richard R.

SchrockJan 4, 1945-For olefin metathesis

Yves ChauvinOct 10, 1930- Jan 27, 2015For olefin metathesis

Kurt WüthrichOct 4, 1938-For biological macromolecules

John B. FennJun 15, 1917- Dec 10, 2010For biological macromolecule

Alan Jay HeegerJan 22, 1936-

For work on

conductive

polymers

Hideki ShirakawaAug 20, 1936-

For work on conductive

polymers

1963

1974

1991

2000

2002

2005

51

1953

What is a Polymer?

Monomers are the basic building units.

These contain

functional groups or double bonds

When two monomers are made to react,

usually in the presence of a catalyst, they

form a dimer.

More monomers join

successively, thus increasing the

length of the molecular chain

The resulting structure is a

POLYMER!

POLYMERS are long-chain molecules made from same repeat units 52

The same polymer can be made to various lengths (molecular weights) !!!

Tools to design properties in polymers:

• Morphology

• Rheology

• Molecular weight

Lightweighting, strength, etc.

e.g. learn from UHMWPE, DUHMWPE

Non-chemical routes

Packaging Innovations- Power of Polymers (1)

53No other material has this kind of veratility

Technical:

• Improved barrier properties

• Printability

Environmental:

• Oxodegradable

• Biodegradabale

• Bio-compostable

• Bacterium that eats PET : Ideonella sakaiensis 201-F6, Kyoto Univ, 11 May 2016

• Enzyme based treatments of plastic waste

Modifications to polymer chemistry

54

Packaging Innovations- Power of Polymers (2)

Increasing global consumption and disposal: A need to accept the right alternatives

55

Food Packaging Innovations (1) - Product Design

In-mould Labelling

• Here, the label gets applied on the packaging surface simultaneously with the plastic manufacturing

• BENEFITS:

• It reduces container weight

• Thereby, reducing eco-burden

Intelligent Packaging-Interactive

• Use of

• oxygen absorbers

• odour absorbers

• CO2 absorbers

• BENEFITS:

• Enhanced retention of nutrition of packaged food

• Enhanced retention of freshness of packaged food

Intelligent Packaging-Display

• Real-time indication of:

• nutritional value

• odour

• Discoloration

• Accordingly, price adjustments

• Instructions for disposal of packaged food items

• BENEFITS:

• Consumer can make informed decisions

56

Food Packaging Innovations (2) - Chemistry based

Bio-based plastics

• Bio-based plastics undergo decomposition in a specified period under composting conditions in industrial facilities

• Made from biomass/avocado seeds, they degrade naturally

• Some commercial examples:

• PLA (Poly Lactic Acid)

• PHA (Poly Hydroxyalkanoates)

• Bio PTT (PolyTrimethylene Terephthalate)

• 40% energy savings in production vis-à-vis their petrochemical counterparts

The Edible Water Bottle: Ooho!

• Launched in Berlin in Sep 2015

• This is the first project of Skipping Rocks Lab, a London-based startupco-founded by Rodrigo Garcia Gonzalez, Guillaume Couche and Pierre Paslier.

• Encapsulates water within a double gelatinous membrane using the culinary technique of spherification

• A new alternative packaging-simple, cheap, resistant, hygienic, biodegradable and even edible

Click here to see a video -https://www.youtube.com/watch?v

=-J68mz2agIA#t=1316/11/2015

Convenience of plastics, while limiting the environmental impact

Section 6 :

Epilogue

PET/PLASTICS ARE A BOON TO MANKIND 57

• Better Stiffness & Impact

• Maintain or improve longevity and wear

• Reduce thermal and electrical conductivity

• Improves Barrier in Packaging

• Better Stiffness & Impact

• Maintain or improve longevity and wear

• Reduce thermal and electrical conductivity

• Improves Barrier in Packaging

Improve Performance

• Add more flexibility to the design process

• Simplify coloring and decorating finished parts

• Decorate “in-mold”

• Add more flexibility to the design process

• Simplify coloring and decorating finished parts

• Decorate “in-mold”

Enhance Design & Appearance

• Eliminate assembly processes, painting and secondary operations

• Improve quality, Create more highly complex parts

• Consolidate parts, save time and money

• Eliminate assembly processes, painting and secondary operations

• Improve quality, Create more highly complex parts

• Consolidate parts, save time and money

Simplify Manufacturing

• No shattering into shards

• No leaching beyond permissible limits

• No absorbing of essential oils

• No corrosion

• No shattering into shards

• No leaching beyond permissible limits

• No absorbing of essential oils

• No corrosion

Safety

• Eliminate human contact with harmful metals

• Use less energy and generate less waste

• Increase opportunities for recycling

• Inherently lightest and further lightweighting

• Eliminate human contact with harmful metals

• Use less energy and generate less waste

• Increase opportunities for recycling

• Inherently lightest and further lightweighting

Reduce Environmental

Impact

Why Plastics?

58No material is perfect. Each material/industry needs to build on its USPs.

PLASTICS are the best compromise in meeting competing requirements.

PET – boon to mankind

As we approach the 10 billion population mark• Pressure on land for food vs fuel vs fibre vs packaging material

• Water security challenges

• Increasing aspirations – for hygiene, modern materials

PET/Plastics helps civilizational progress:• Lowest ecological footprint compared to paper, textiles, glass or metals

• Safest – no leaching

• Most convenient (non-fragile, lighter, versatile, cost-effective)

• Recyclable

• Amenable to innovations

• Releases land for much needed requirements of food 59Plastics: Release land for food and meet the increasingly aspirational society

60

Acknowledgements

Ms. Swati Verma

Reliance Ind. Ltd. PET Business

Dr. Sunil Mahajan

Reliance Ind. Ltd. Polymer Business

Mr. Bidhankumar Pradhan

Reliance Ind. Ltd. PET Business

Can there be a better way to demonstrate the utility of PET/Plastic packaging? 62

Innovation and Product Safety: Plastics are the drivers in the new INDIAN economy 63

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