waste management a packaging perspective
TRANSCRIPT
Waste Management (A Packaging Perspective)
Colm Munnelly
Packaging Technologist
Irish Biscuits Ltd.
December 2002
Who are Irish Biscuits?
• IBL formed in 1966 by merger of Jacobs (1851) and Bolands Biscuits (1957)
• Employ over 600 people
• Manufacture over 50 types of biscuit
• Turnover circa 100,000,000 euro
Packaging Waste legislation
• Waste Management (Packaging) Regulations 1997: (“Designed to assist and promote the recycling of packaging waste” -SDCC)
• Two Real Options:
– 1. Comply with the legislation independently
and report to the local authority.
– 2. Participate in a Waste recovery scheme
operated by an approved body (Repak)
1. Legislation Requirements:
• Provide information on annual turnover
• Provide information on location of premises
• Provide information on weights of packaging materials
• Display notices
• Provide facilities to accept, collect packaging waste
• Return waste to suppliers
• Recover or make waste available for recovery
• Prepare, publish plans and reports
• Submit information monthly to local authority
2. Obligations of Repak Membership:
• Provide data on packaging material twice a year to Repak
• Pay invoices
• Join Green Dot scheme
• Deal responsibly with waste
• Inform Repak of changes to systems
• Allow system to be audited for Repak
Advantages of Repak Membership:
• Obligations complied with as a group
• Green Dot membership
• Approved Contractor Scheme (Rebates)
• Audit chain for each contractor
Sources of Physical Waste at IBL• Food Waste
– Dough– Dry Biscuits– Processed Biscuits
(with Cream/Chocolate/Mallow)
• Packaging Waste– Input Packaging– Output Packaging– WIP (Work in Progress)
Sources of Packaging Waste• Goods Inwards
– Bulk Material
– Palletised Ingredients
– Minor Ingredients
– Packaging
• Factory Produced– Input Packaging
– Output Packaging
• Warehouse / Shipping– Pallets
– Stretchwrap
Packaging Material Types
• Cardboard Corrugate, Cartonboard etc.
• Paper Liners, Inserts, Menu Pads
• Flexible Plastic Film Wrapper Reels
• Other Plastic Tubs, Trays
• Metal Tins
• Glass Bottles
• Wood Pallets
Waste Hierarchy
Reduction / Minimisation
Re-use
Re-cycle
Reclaim
Landfill
1. Reduction / Minimisation • 1. Reduction of input packaging
• 2. Gauge reduction on film, trays, tins, tub
• 3. Reduction of outer case board grades
• 4. Increased number of packs per outer case
• 5. Pallet volume optimisation
2. Re-use
• Returnable containers for trays, tubs
• Increased use of Recycled (Test) board in outer cases
• Maximum usage of pallets (Increased use of CHEP) (wooden for goods outward)(plastic on factory floor)
3. Re-cycle
• Corrugated Cardboard Smurfit Re-cycling
• Cartonboard Smurfit Re-cycling
• Flexible film Dilloan Recycling
• Other plastic Re-Tech Processing/Dilloan
• Metal Hammond Lane
• Glass (Negligible amounts)
• Wood Pallet Services
4. Reclaim
• Awaiting options for incineration
• Input packaging on colours/flavours
• Removal of pvc and pvdc material
5. Landfill
• Compacted, unsegregated waste from the factory floor goes to landfill through Ipodec
• Any material left that does not have a re-cycling option is landfilled.
• Cost of landfill (Direct and Indirect)
Internal Packaging Waste
0
50
100
150
200
250
Total Internal waste Waste to Landfill
Internal Waste Management
To
nn
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‘Repak Member of the Year’
• Packaging waste considered at product design stage
• Emphasis on Reduction and Re-use• Sourced re-cycling options for all of our
packaging materials• Encouraged contractors to join subsidy
scheme• Reduced tonnage to landfill by 10% in 2001
Packaging Fees
0500
100015002000250030003500
InputPackaging
InternalW aste
OutputExport
OutputIreland
Type of Packaging
To
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es
What winning has meant to IBL• Turns Repak into something positive
• Recognition for past efforts
• Establishes momentum
• Helps overcome ‘difficult’areas
• Helps publicise re-cycling efforts throughout the company.
Future plans in IBL• Further investment in bailing/compacting
• Roll out of recycling to more ‘difficult’ areas
• Design for recoverable/recyclable packaging
• Holistic projects
– Less input packaging
– Optimum product in packets
– Optimum packets in cases
– Optimum cases on pallets
Challenges
• Options to recycle in Ireland and to market recycled product in Ireland.
• Current weight based system does not allow for mixes of virgin/recycled material.
• Recycled material does not mean cheaper material.
• Conflict between marketing concerns and environmental concerns.