The Future of Packaging

From Linear to Circular

Tom Szaky

• Publisher: Berrett-Koehler Publishers
• Year: 2019
• ISBN:
  9781523095520
• Edition: 1
• Topic: Business
• Subtopic: Manufacturing
• Index: Business

Only 35 percent of the 240 million metric tons of waste generated in the United States alone gets recycled, according to the Environmental Protection Agency. This extraordinary collection shows how manufacturers can move from a one-way take-make-waste economy that is burying the world in waste to a circular, make-use-recycle economy. Steered by Tom Szaky, recycling pioneer, eco-capitalist, and founder and CEO of TerraCycle, each chapter is coauthored by an expert in his or her field. From the distinct perspectives of government leaders, consumer packaged goods companies, waste management firms, and more, the book explores current issues of production and consumption, practical steps for improving packaging and reducing waste today, and big ideas and concepts that can be carried forward. Intended to help every business from a small start-up to a large established consumer product company, this book serves as a source of knowledge and inspiration. The message from these pioneers is not to scale back but to innovate upward. They offer nothing less than a guide to designing ourselves out of waste and into abundance.

CHAPTER 1

Plastic, Packaging, and the Linear Economy

Attila Turos

Former Lead, Future of Production
Initiative, World Economic Forum

IMAGINING A WORLD WITHOUT PLASTIC IS NEARLY IMPOSsible. We interact with it from the moment our digital clocks, smartphones, smart speakers, and Wi-Fi-enabled coffee makers wake us up, to the time we sleep on memory foam mattresses and microfiber sheets. Paper coffee cups are lined with it, razor blades are now forged of it, and lifesaving medicines and treatments are administered and delivered by it in more configurations than ever before. Industries once dominated by metal and other naturally occurring materials (like wood and cotton) have been taken over by plastic, which now makes up roughly 15 percent of the average car by weight and about 50 percent of jets like the Boeing Dreamliner.¹

Consumers are often surprised to learn just how pervasive plastic is across the entire economy. The corkboard you have hanging on your wall? Cork-colored plastic. Your kid’s synthetic fur plush toys and stuffed animals? Plastic. The core of your “wood” door is made of polyvinyl chloride (PVC) and insulating plastic foam. The textiles of nearly every item in most of our closets are majority oil-based fiber, and very few of us are actually “burning rubber” with our vehicles when we speed off to our next appointment.

Business is largely responsible for this shift. In fact, one of the first man-made plastics was the result of a commission to find an alternative material for school blackboards in the late 1800s,² an anecdote illustrative of industry’s close ties to the development of plastic as the favored medium for business. Items once carved out of a solid block of wood, forged of steel, or spun out of wool can be more easily made from plastic, which is lighter, stronger, and less expensive to produce, an aspect that has numerous functional, aesthetic, and economic advantages for both companies and consumers.

Modern life now is dependent on the fossil fuel by-product, as the American Petroleum Institute’s 2017 “Power Past Impossible” Super Bowl ad reminded the public.³ The ad shows a robotic prosthesis pulling an arrow firmly back in a bow to reveal itself attached to a young woman. High-contrast blue and magenta of an electrocardiogram displays the beat of an artificial but fully pumping heart valve. An image of a rocky golden landscape is reflected in the helmet of an astronaut who, backlit by fog and sparks, walks away from us, with a pack sporting a decal of the American flag.

A Material of Substance

The spirit of these forward-thinking innovations can be traced back to the discovery and inspired use of natural, bioderived substances such as rubber, egg, and blood proteins by ancient artisans and craftsman (manufacturers in their own right) as early as 1600 BCE.⁴ Cutting-edge for their time, the useful behavior of these plasticlike compounds sealed the roofs of dwellings, made containers and pots, and banded goods together for transport, offering an alternative construction material for the business activities of early humans. Since then, plastics have evolved into myriad man-made material types,⁵ poised to address changing needs, as well as gaps, in a competitive market.

Synthetic polymers have been disrupting commodity industries for well over 100 years. John Wesley Hyatt patented Celluloid in 1869,⁶ a commercially viable solid, stable nitrocellulose used to make things like billiard balls, false teeth, combs, jewelry, and piano keys; it had a comparable performance and look, a more secure supply chain, and a much better price point than the more expensive conventional materials. Celluloid could be rendered to resemble ivory, tortoiseshell, marble, ebony, and semiprecious stones. Interestingly, Hyatt’s company boasted in one pamphlet, “It will no longer be necessary to ransack the earth in pursuit of substances which are constantly growing scarcer.”⁷

Then in 1907 Leo H. Baekeland, called “the Father of the Plastics Industry,” developed Bakelite, the world’s first synthetic, durable plastic.⁸ Solid and sturdy, it was a favored material for high-value products like radios, telephones, toys, and game pieces; later it was used for wartime equipment such as pilots’ goggles and some parts of firearms well into the 1940s. By then the improvements in chemical technologies that burgeoned in World War I were combined with the leaps in mass production made in WWII, setting the stage for the modern economy of plastics we see today.

Plastic Fantastic

It was this moment, when plastic went from being a prototype, premium material to a viable, cost-effective mode of producing consumer products, that manufacturers’ uses for it became limitless. Injection-molding machines turned raw plastic powders or pellets into a molded, finished product in a one-shot process. A single machine equipped with a mold containing multiple cavities could pop out 10 fully formed products, like combs or flooring sheets, in less than a minute.

Coming out of wartime, output quotas long dedicated to government and the military machine were suddenly freed up for a plastics industry poised to break into an untapped market: civilians. After the war, according to one executive, “virtually nothing was made of plastic and anything could be.” Soon synthetics factories were churning out Tupperware, Formica tables, polyester fast fashion, lifesaving Kevlar vests, and new toys like hula hoops, Legos, and Barbie. By 1960 plastics had surpassed aluminum, becoming one of the largest industries in the United States; in 1969 Neil Armstrong planted a nylon flag on the moon.⁹

Plastic has been the key enabler for sectors as diverse as packaging, construction, transportation, health care, and electronics. It’s a simple way to mass-produce goods that once needed to be carved, welded, or blown out of heavier, more laborious material. Plastic packing and packaging material allows delicate items like food, medicine, and clothing farther distribution and easier handling. Polymers give body to common household items like insulation, piping, putty, and paint. Plastic increases consumer access to products and services both literally and financially, driving consumption. Innovation thrives with it, as industry has come to depend on it. SEE 1.1

1.1 This table of main resin types, categorized by numbers 1 through 7, illustrates the pervasiveness of plastic in the modern economy.

World Economic Forum

The challenges of decoupling plastic from production and innovation as we know it would be eclipsed only by consumers trying to live without it. Today nearly everyone comes into contact with plastics, especially plastic packaging—its largest application, representing 26 percent of the total volume of plastics used.¹⁰

Plastic and the Linear Economy

While delivering many benefits, the current plastics economy has drawbacks that are becoming more apparent by the day. For instance, with more than 280 million metric tons of new, virgin plastic produced globally per year,¹¹ only 14 percent of all plastic packaging is collected for recycling. When additional value losses in sorting and reprocessing are factored in, only 5 percent of the material value of what we often use only once— single-use plastics—is retained for the next time around.

Plastic recycling has not kept pace with the continued demand for plastic production, which would be offset by the capture of more of this discarded material. And the problem is growing: today we produce 20 times more plastic than we did in 1964, and that volume is expected to double again in the next 20 years—and almost quadruple by 2050, the same year that plastics will outweigh fish in the world’s oceans.

Nearly every product and packaging innovation has been brought into modernity with materials and designs that global recycling systems cannot handle, and consumer products companies are producing more materials that end up in landfills than ever before. Circular systems of reuse—vesting products with value and striving to keep them at high utility—have fallen in favor of largely linear ones that, despite the sophisticated science and technology behind them, view products and packaging as disposable, or designed to be thrown away.

Simply Circular

It wasn’t always like this. Products and packaging used to cycle through a more regenerative circular economy, where, as in nature, things didn’t go to waste. In contrast to the linear economy, this make-use-recycle-remanufacture concept creates value at each stage of a product’s circular life cycle as recovered materials are returned to productive use. Here it is important to remember that waste in itself is a relatively modern idea that came about when it became more economically viable to produce new materials than to repurpose existing ones—and to burn and bury the rest. Up until the 1940s, when mass production, shifts in consumerism, and plastics came into play, things were actually quite circular. SEE 1.2

Dairy distributors provided reusable glass bottles that customers could empty and then leave on their doorsteps in the cultural motif we know as “the milkman.” These glass bottles, which flowed through a system in which the producer was responsible for them (and owned them as an asset), had a high rate of reuse. So did durable containers provided by consumers for producers to fill with their purchases of other consumables such as oil, eggs, and cream.

What consumers didn’t have delivered, they would shop for, and buying groceries and household items worked in the same way: either the patron or the producer provided reusable containers and wraps that could be returned, cleaned, and used again for the next batch. The concept of dual-use packaging, structurally designed to serve a function after first product use, got products off shelves by giving consumers “more for their money”; examples are condiments sold in decorative crocks and dry goods sold in reusable cloth bags or tin canisters. An emerging consumer culture encouraged more buying and selling, so producers sold “two products for the price of one,” innovations of marketing and design that carried well through the Great Depression and far into the 1960s.

1.2 It was once intuitive that materials, resources, and products should reused, repaired, and recycled in what we call the circular economy.

European Commission

But companies eventually realized that sales need not be contingent on the flow of reusable containers. So, to make products easier to buy, use, and be needed again, they adopted packaging that took what couldn’t be placed unwrapped in a cart, basket, or pack and made it marketable and easier and cheaper to buy.

Single-Use Packaging

Lighter and more portable than thick refillable glass bottles, commercial metal cans and tins used to store and preserve food (a revolution that afforded larger ...