packaging audits and packaging reduction workplans - guidelines
TRANSCRIPT
CCMECanadian Council Le Conseil canadien
of Ministers . des ministresof the Environment de I'environnement
'.
'PACKAG.ING AUDITS
8.nd'
PACKAGINGREDUCTION".WORKPlANS'
Guidelines .to help industry meet t~e goals. of ~heNational Packaging Protocol
Code
RECYCLEDCONTENT
(%)'
Packaging Material
Tota'
EPC-NAPP-44E .
JUNE 1992
.' The CanadianCouncilof the Ministersof theEnvironment(CCME)is the major '.
intergovernmental forum in Canada for discussion.andjoint action on envIronmentalissuesof . . .
national, internationaland globalconcern. .'
. Environmentalministersfrom each of the tenprovinces, the fedeICilgovernment and the two
. territoriesparticipatein meetingsat least twicea
.year. They discus~ environmental issues,exchange information, make decisions and .
establish .policy for work to be ~ed.out underthe auspicesof CCME. .
Canadian. C(n~ncilof Ministers of the.Environment Secretariat326 Broadway, Suite 400Winnipeg, ManitobaR3C OS5 .'
*. 100% recycled paper, all post-consum~r fibre
EPC-NAPP-44EISBN 0-919074-65-0
* Disponible en fran~is
'j
Packaging AuditsandPackaging.Reduction Workplans
Guidelines to help industrymeet the goals of the .
National Packaging Protocol
Canadian Council of Ministers of the Environment(CCME)
EPC-NAPP-44EJune 1992
Foreword
These guidelines have been prepared by the National Task Force on. Packaging. The Task Force is a "multi-stakeholder"group consistingofrepresentatives from fedeniI, provincial, territorial and municipalgovernments as well as environmental, industry and consumer groups.
The Packaging Audits and Packaging Reduction Workplans along withthe related document,Canadian Code of Preferred Packaging Practices(CCMEEPC-NAPP35E, November 1991), are part of the Task Force'scommitmentto helpingpackagingproducersand users achievethe targetscontajnedin the NationalPackagingProtocol. .
Special mention.must be made of the important work of the WasteReduction Office of the Ontario Ministry of the.Environment in draftingthis document .and Synthesizing the comments of Task Force members andtwenty industry associations. . .
ii
Table of Contents
Foreword it
1. Introduction 1
1.1 Background1.2 Purpose1.3 Responsibilityfor CompletingAudits1.4 Definitions
1113
2. The Packaging Audit .4
2.1 Key Features2.2 Sources of Data2.3 What to Include in the Audit2.4 Completing the Packaging Audit Report Forms
2.4.1 The Packaging Audit Worksheet2.4.~ The Packaging Audit Summary Sheet2.4.3 The PackagingAuditCover Sheet .
2.4.4 SampleForms .
45.56.68.88
3. Preparing a Packaging Reduction Workplan 14
3.1 Key Features3.2 . Sourcesof Data3.3 What to Includein the Workplan .
3.4 Completing the Packaging Reduction Workplan Forms3.4.1 The Workplan Worksheet3.4.2 The Workplan Summary Sheet3.4.3 SampleForms .
14.141414141515
4. Suggestions for Developinga Packaging Reduction Wo~kplan 22
4.1 Reduction4.2 Reuse/Recycling.
2223
Appendix A: Statistics Canada Packaging Material Categories 25
Appendix B: &tablished RecyclingRates for Packaging M~terials 28
Appendix C: Forms 29
iii
1. Introduction
1.1 Background
The National Task Force on Packagingwas established by the Canadian Councilof Ministers of the Environment (CCME)in 1989, to develop a National PackagingPolicy for Canada within the context of amuch broader total waste managementstrategy. The result was the NationalPackaging Protocol (NAPP), which wasformally adopted by CCME in March1990. .
The Protocol outlines six fundamentalpolicy statements aimed at minimizing theenvironmental effects of packaging andreducing packaging waste generation inCanada by 50% by the year 2000, relativeto a base year of 1988. A 20% reductionby December 31, .1992 and a 35%reduction by December 31, 1996 havealso been established as interim targets.
The goals and objectives of the Protocolapply to all packaging consumed in
. Canada, regardlessof its origin. Inaddition to these national goals, specifictargets will be established for industrysectors. The goals will be achievedthrough promoting and applying theprinciples 9f source reduction, reuse, and.recycling (Three Rs). It should beunderstood that there is a hierarchy withinthe Three Rs. Source reduction is thepreferred option followed by reuse andthen recycling. .
It is recognized that certain essentialfunctions of packaging may limitopportunities for reducing packagingwaste. These include the need to protectthe health and safety of consumers, tomeet language requirements and provideinformation about the product, and tomaintain the integrity of the product.
Under no circumstances should theseessential functions of packaging becompromised for packaging wastediversion objectives.
1.2 Purpose
In November 1991, the Canadian Code.of Preferred Packaging Practices wasreleased by th~ CCME. This documentoutlines a voluntary approach that industrycan take to modify packaging practices ina manner consistent with the goals andobjectives of the Protocol, emphasizingthe use of source reduction, reuse, andrecycling. .
These packaging audit guidelines are atool to assist brand owners, whethermanufacturers or distributors, to assessand quantify the amount of packagingused to package and market their .products. The audit will also provideessential information that companies willneed to prepare packagingreduction .
workplans. These workplans are designedto minimize the amount of packagingused; and maximize diversion of thepackaging waste that results fromconsumption of the companies' packagesby the industrial and household consumer.
1.3 Responsibility for CompletingAudits
Although it is recognized. that allstakeholders play a role in reducingpackaging waste in Canada, it is generallyagreed that brand owners of packagedgoods have the most control over theamount and design of packaging used tomarket a specific product. Brand ownerscan take specific steps to reduce theimpact of packagIng on the waste stream.
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Brand owners who do not actuallymanufacture the products in question cannevertheless influence the type andamount of packaging used. They are alsoresponsible for the packaging that willrequire a reuse or recycling infrastructure,or disposal. For the purpose of theseguidelines, a brand owner may be amanufacturer, distributor, or importer ofproducts. .
Brand owners should use these guidelinesto investigate the following opportunitiesfor reducing packaging waste:
. eliminatingor minimizingthe amountofnew packagingused to market theirproducts;
· reducing the amount of new packagingused by selecting or del)igningpackaging that is reusable, wheneverpossible;
· selecting or designing packages that. enhancerecyclability,and ensuringthat
the packages are, in fact, recycled.
Importers can reduce packaging waste byselecting products whose packaging isconsistent with the NAPP goals, wheneverpossible.
Packaging audits will provide theinformation that a company needs in orderto develop a comprehensive workplan toreduce its packaging use. Much of theinformation collected in a packaging auditis the same as that required by theNational Task Force on Packaging in itsbiennial surveys to collect data onpackaging in Canada. Companies shouldtherefore already have the information.
These guidelines do not attempt to controlthe types of packaging being used, butrather to provide a standard format forestimating packaging use on a company-wide basis. The Packaging Audit andPackaging Reduction Workplan reportsdo not refer to specific targets to be met,but rather attempt to encourage the "bestefforts" by companies to reduce packagingwaste.
These guid~lines are consistent with theNational Packaging Protocol and theCanadian Code of Preferred PackagingPractices and should assist companies toachieve or exceed.the national packagingwaste diversion goals set out in theProtocol. The Protocol does not requireindividual companies to meet these targetsbut will focus on broader industry sectors.
The monitoring of progress in achievingpackaging waste diversion is an importantpart of the total waste managementprocess. The following is some of theimportant information that the audits andworkplans will provide:
· a well-based and up-to-date estimate ofprogress in reducing packaging use;
· estimates of the potential for. reducingpackaging waste in future years;
· the cost and other implications ofinitiatives to reduce packaging waste;
· a clear understanding of industry'slimitations/barriers and why thepotential for packaging waste reductionmay be limited in some instances.
2
. 1.4 Definitions .
· Package or packaging refers to amaterial or item that is used to protect,contain, or transport a commodity orproduct. A package or packaging canalso be a material or item that is
physically attached to a product or itscontainer for the purpose of marketingthe product or conveying information
. about the product. .
· Packaging Audit is a study.thatidentifies and measures all thepackaging materials and packaging usedby a company.
· Packaging Reduction Workplan is anorganized plan of work that whenimplemented will ~inimize the amountof packaging used, resulting in l.esspackaging waste generated. The planshould describe specific activities,timetables, and expected results.
. I
· Reuse in this guideline refers topackaging that comes from anotherestablishment for use again in itscurrent form.
· Brand OWner is the person or companywithin a province responsible Jorintroducing a particular product to themarketplace. A brand owner may be amanufacturer, distributor, or importer
. of products.
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. 2;. The Packaging Audit
Companies will generally carry out aPackagingAuditand prepare a .
Packaging Reduction Workplan everytwo years. The audit will measure thecurrent packaging use, as well as estimatepackaging used in 1988.
In addition, it will assist companies to .
determine the amount of their packagingwaste that is generated by consumers inboth the current year and the base year of1988. . ·
During the development of the NationalPackaging Protocol, 1988 was selected asthe .base year from which progresstowards targets will be measured. Thisbase year is entrenched in the Protocoland should not change. For the purposeof the packaging audit, however, if datafor 1988 are not available, any other yearfrom 1988 to the present, for which gooddata are available, may be used as a baseyear. A later base year may be used if acompany was riot in business in 1988.
2. 1 . Key Features
The audit process and audit forms aredesigned to be as simple as possible,while providing useful information.andenabling companies to measure all typesof packaging reduction and packagingwaste diversion initiatives undertakensince the base year.
Packaging material use, reuse, recyclingrate, and recycled content are reported foreach packagingtype. ..
Although packaging weights are reportedin absolute terms, it is important that thedata also reflect any change in producti()nor sales levels by the company. For thisreason, an adiusted packaging reduction is
also reported to account for any swings inproduction from year to year. Tocalculate this, worksheets must becompleted for each product, or each
. similar type and size of package.. . .
By comparing the amount of newpackaging used in the current year withthat used in the base year, it is possible tomeasure any source reduction that hasoccurred. While source reduction is thepreferred. option for reducing the amountof packaging that ultimately requiresdisposal, it is not always possible.
Similarly, the weight of reused material inpackaging is recorded for the base yearand can be compared with the weight ofreused material in the current year.Reuse of material results in directdiversion from disposal, with the mostcommon example being the refillablebeverage container.
The probability of a specific packagebeing recycled depends on a number offactors that are often beyond the controlof the company that introduced thepackage to the marketplace. Also, whileit is possible to estimate a recycling rate.for a particular material or packagingtype, it is generally very difficult to
. calcuiate the recycling rate of a specific.package of a specific company. Despitethe above limitations, it is important toreport the recycling rate in the packagingaudits, since recyclingis a major .
component of packaging waste diversion(see Appendix B). A company caninfluence the recycling rate of itspackaging in several ways, such asselecting recyclable materials and
. ensuring that the complete package isrecyclable, or by contributing to arecycling funding program.
4
The use of recycled content in packagingmaterials 'is actively encouraged, since itprovides a market for recycled materialsand, in effect, contributes indirectly towaste diversion. Recycled content isreported as a percentage for the base orprevious year and also for the current .
year.
Reporting packaging material use, reuse,recyclability and recycled content for aprevious year .and the current year willenable comparison between the two years.However, no attempt will be made .to totalall diversion measures to calculate the netpackaging reduction or diversion fromdisposal~
Categories for packaging material arebased on; and consistent with, thecategory list contained in the StatisticsCanada Survey (See Appendix A). Ifpreferred, companies can.use a "macroapproach" to estimate the amount ofpackagingused for each packaging .
category. For example, rather thanreporting all the different types of foamplastic used under 2.61, 2.62 and 2.63 onthe form, the total amount of foam plastic'can be reported under 2.6..
2.2 Sources of Data
Production or purchasing records are thebest source of data for determining theamount of packaging used. For thecurrent year and all subsequent years, thisamount should be determined by totallingthe number of each size .and type ofshipping unit produced or purchased. Forexample, if a company manufactures ordistributes canned soup, all those productsusing the same type of package should belisted, Le., 24 x 10 oz. cans. It wouldnot be necessary to list all varieties
producedor purchased. .The weight ofeach of the packaging components caneasily be calculated from this total,provided that the unit weight of eachcomponent is known. The unit weightcan be obtained from the manufacturer ofthe packaging material or by weighingeach component on a scale.
Ideally, the same method should be usedto determine the amount of packagingused for the base year of 1988. Ifpackaging design has changed since thebase year, it will be important to knowthe correct unit weight factors applicableat the time. Suppliers of packagingmaterial can help in this respect.Alternatively, the unit weight can be
. reasonablyestimatedby usingcurrent unitweights adjusted by any weight differenceresulting from design changes. If theserecords are not available, sales records,purchases, receiving records, etc. shouldall be considered as sources of data fromwhich to estimate the amount of.packaging used in 1988. The objective.should be to estimate the amount ofpackaging used in 1988 as accurately aspossible, based on the records available.
. If there has been little or no reductiQninpackaging since 1988, or if no records areavailable, any year from 1988 up to andincluding 1992 may be selected as a baseyear.
2.3 What to Include in the Audit
The audit should include all packaging. and packagingmaterialsused by thecompany to package products. Allcomponents of the products' packaging,including primary and secondarycontainers, closures, dispensing orapplicator attachments, labels, shippingcontainers, partitions and dividers should
5
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be audited, as well as material used f.orunitizing shipments, such as pallets, slipsheets, shrink .or stretch wrap film, metal.orplastic strapping, bulk c.ontainers,shrouds and caps. If it is n.otp.ossiblet.oallocate weights .ofunitizing material t.oindividual Packaging Audit W.orksheets,they may be rep.orted as an .overall t.otal.on the Summary Sh~t.
Packaging materials used by suppliers t.oship their products t.othe auditingc.ompany sh.ouldn.otbe included in thepackaging audit.
2.4 Completing the Report Forms
The packaging audit rep.ort consists .ofthree f.orms: the Packaging AuditW.orksheet, the Packaging Audit SummarySheet and a c.over sheet (blank f.orms canbe f.oundin Appendix C).
2.4.1 The Packaging Audit. Worksheet
One .of these sheets.must be c.ompletedf.oreach distinct package type .or size. It i$n.ot important h.owmany product typesuse the particular package type .or size, asl.ong as the packages are the same.
Linel.
Enter Current Year. (The year t.owhichthe audit refers)
Line 2~
Enter Base Year or Previous Year. This
will change each time the audit isc.onducted. After c.ompleti.on.of the firstaudit, the base year will, in effect, be theyear in which the previous audit wasconducted. .
Line 3.
Enter Company Name.
Package Description. Use any f.ormatthat best identifiesthe specificpackagetype and size, e.g.; "12 x 10 .oz.s.oupcans", .orsimply "12 x 10 .oz.can." Thedescripti.onsh.ouldbe applied t.othe finalshippingunit, whetherthis is a c.orrugatedcase, bag, bale, etc.
Line4.
Units in Base Year. Rep.ortthe t.otalnumber .ofthese shippingunits produced.
.orpurchased in the base year. Include allpr.oducts packed in this specific type .ofpackage.
Units in Current Year. Rep.ort the samedata f.or the current year. .
Line 5.
Adjustment factor. This is .obtainedbydividing the number .ofunits manufactured.orpurchased in the base .or previ.ous yearby the number manufactured .orpurchasedin the current year. This fact.or is used t.oadjust the current year's pr.oducti.on.or
. distribution levels t.oth.ose.of the previ.ousyear t.oall.owa direct c.omparis.ont.obemade. .
Main Table.
The left-hand c.olumn is headedPackaging Material Category. Materialsused sh.ouldbe entered in this c.olumn,t.ogetherwith the material categ.ory c.ode,based .onthe Statistics Canada Survey list..For a list .of material categ.ories andc.odes, refer to Appendix A. If unitizingmaterials such as pallets, stretch wrap,and banding can be accurately allocated t.o
6
individual worksheets, they should berecorded here. If this is not possible, thecompany's total usage of these materialsshould be summarized on the SummarySheet. In this case, it will be necessary touse an average Adjustment Factor toarrive at the Adjusted PackagingReduction. This can be done by dividingthe overall base year's productionor '
distribution by the overall current year'sproduction or distributi~n, oralternatively, by taking a weightedaverage of the individual adjustmentfactors on the worksheets.
Starting with the first packagingcomponent, enter the appropriatepackaging material description in the left-hand column. Either a detailed
description (micro) or general materialcategory (macro) can be used. Succeedingcolumns are filled in opposite thiscategory as follows:
New Material Used in Base or PreviousYear - Record the weightof newmaterialused in tonnes. See" SourcesofData" (Subsection2.2) for ways to obtainthis data.
New Material Used in Current Year -Record the amount of new material in thispackaging compOnent in the current year.
Adjusted Weight - Multiply the weight ofnew material used in the current year bythe Adjustment Factor.
Packaging Material Reused in BaseYear -Record the weight in tonnes. Thisis the weight of material that has alreadybeen used at least once and has comefrom another establishment for' reuse in itssame form.
Packaging Material Reused in CurrentYear - Record the weight in tonnes.
Adjusted Material Reused -Multiply theweight of material reused .in the currentyear 'by the Adjustment Factor.
Recycling Rate - The recycling rate mustbe based on an established recyclingsystem and must represent that proportionof the total packages produced that islikely to be recycled. Companiesclaiming these rates must be able tosupport their claim if requested.Alternatively, recycling rates developedby the National Task Force on Packagingmay be used (see Appendix B).
Recycled Content - Report the percentage ,
of recycled content in each packagingcomponent for the base or previous yearand for the current year.
Comments - Space is provided at thebottom of the worksheet for commentsand explanations regarding audit results.This space can be used to indicate howreductions ~ere achieved, or why theycould not be achieved.
Special Situations
.. If a whole packagetype isdiscontinued, the AdjustmentFactorshouldbe markedwith NIA and theAdjustedWeightcolumn shouldbe leftempty.
· If a new package type is,introducedbefore the current year, and was notincluded in the base year, theAdjustment Factor should be marked asabove and th~ Adjusted Weight column
, shouldbe left empty.
7
· If, between the base year and thecurrent year, a package type is ch~gedin size specifically to reduce packaging,the followingprocedure shouldbe '
followed.
Enter the new package description onthe worksheet. Under, comments,describe the natureof the changeand '
describe the package being used in thebase year. The number of units of thenew package manufactured in thecurrent year should be reported in theusual way with' the equivalent numberof units manufactured reported for the,base year. As an example, if 800,000cases containing 12 bottles, wereproduced in the base year'and-5oo,000cases containing 24 of the same bottles
, were manufacturedin the current year;the current year would be reported as500,000, but the base year would be
, reported as 400,000 (4oo,OOO~uivalentcases of 24 bottles). The AdjustmentFactor is then calculated as usual.
This procedure may be applied tochanges in shipping case sizes, ,as wellas increases in container sizes toaccommodate larger volumes orreduction in container sizes due to
product redesign, .provided that the newtype of package completely replaces theold type.
2.4.2 The Packaging Audit SummarySheet
, From the packagingaudit worksheets,total the weight of material used for eachcategory in the base or previous year andin the current year and record in the' ,appropriate column in the summary sheet.
Since recycled content"may vary betweendifferent packages made of the samematerial, total recycled content cannot bereported on the summary sheet unless thepercentage for a material type is the sameon each worksheet.
Enter the total of all columns recordingweights at the bottom of the sheet.
2.4.3 Packaging Audit.. Cover Sheet
ThIs sheet should be completed with allthe information requested and signed byan officer of the company.
N.B. It is important to record how tp.e 'base year figures for new materialused ,
were determined~,Le., production recordswith known component unit weights,estimated unit' weights, purchases, sales,etc. This information will indicate thereliability of usage totals for the baseyear. '
2.4.4 Sample Forms
The following are sample PackagingAudit forms. The company carrying outthe audit is AcmeWidgetsInc. The '
company is carrying out an audit ofpackaging materials used during 1992, thecurrent year, and it has selected 1988 asits base year. This informationis '
included at the top of both the summarysheet and the worksheets. '
Acme has produced two products, widgetsand clea,ning fluid, since 1988.
· Widgets are packaged'l 00 in,a foldingcarton. This carton' is overwrappedwith a polypropylene film, and 12 ofthese units are packed in a corrugatedshipping ca~e. The package description
8
has therefore been entered as 12 x 100
widgets. Details of packaging used forwidgets are given on Worksheet #1.
· Cleaning fluid is packaged in 500-mLplastic bottles with plastic caps and 12bottles are packed in a corrugatedshipping case. Worksheet in givesdetails of this .product's packaging.
Worksheet #1
. In 1988, Acme produced or distributed725,000 cases of widgets, Le., 725,000 x12 x 100 widgets. In 1992, productionhad increased to 850,000 cases. Thesenumbers are reported under PackagingUnits in Base Year and Packaging Units
. in Current Year. "TheAdjustment Factorof .853 is "calculatedby dividing the BaseYear's Units by the Current Year's Units.
The packaging components are listedaccording to the Statistics Canadadescriptionsin the left-handcolumn, "
together with the material category codes.These are obtained from Appendix A.
In 1988, Acme used 11.17 tonnes offolding cartons as new material. Justbefore 1992, Acme reduced the calliper ofcardboard"used in the folding cartons by10% to reduce packaging. In 1992,however, their prOduction had increasedand they actually used more new cartons.In fact, 11.79 tonnesof cartons were .
used. The Adjusted Weight is calculatedby multiplying 11.79 by .853 == 10.057
In 1992, the folding cartons contained100% recycled material and had arecycling rate of 5 %. These figures arereported in the appropriate columns.
. The film overwrap used to protect thefolding cartons did not change between
1988 and 1992, but because of theincrease in production or distribution, theusage increased. When the AdjustedWeight is calculated however, a zerochange results.
In 1988, Acme used 1.96 tonnes.ofcorrugated cases to ship their widgets.Corrugated cases are recyclable. In 1992,2.26 tonnes of corrugated cases were usedand the recycling rate was at 40 %. ThecorrUgated cases contained 10% recycledmaterial.
In i988, 2 tonnesof wood pallets wereused and there was no reuse. In 1992,1.34 tonnesof new palletswere used and1 tonne was reused.
Worksheet #2
In 1988, Acme produced 800,000 cases ofcleaning fluid, Le., 800,000 x 12 x 500mL bottles. In 1992, this had increasedto 1,000,000 cases. These numbers areentered on Worksheet #2 and theAdjustment Factor of .800 is calculatedby dividing the Base Year's Units by theCurrent Year's Units.
In 1988, Acme used 42.40 tonnes ofplastic bottles. In 1990, the companyreduced the wall thickness of the bottles
by 15%, but in 1992 their production hadincreased. In the example, there was norecycling of the bottles. Since 1991,however, the bottles have contained 10%recycled material.and this is shown as a
"percentage in the appropriate column.
In 1988, 9.60 tonnes of caps were usedand, since no reduction occurred; theincrease in weight during the current yearwas due entirely to the increase inproduction or distribution. The caps werenot recycled and contained no recycled
9
content.
In the base year, 20 tonnes of corrugatedcases were used and in 1992, 25 tonneswere used. When the numbers areadjustedto reflect packageusage in the .
current year at 1988 levels, the reductionis zero. In 1992, the recycling rate forcorrugated cases was 40% and contained10% recycled material. In 1988, thecases contained no recycled material, butthis increased to 10% in 1992.
In this example, 30 tonnes of new wood.pallets were used in 1988 and 1 tonne wasreused. In 1992, 27.5 tonnes of newpallets were used and 10 tonnes werereused.
Summary Sheet
The summary sheet shows the currentyear, the base year, the company name,and the number of worksheets included(2).
In the left-hand column, the packagingcomponents from both worksheets arelisted, as well as such items as stretchwrap film and pallets which were used forunitizing both products for shipment.
Each of the packaging types reported onthe worksheets is listed on the summarysheet and the values for new material useare added. .
Unitizing materials are included on thesummary sheet as a separate item. Ac.meuses stretch wrap film to consolidateits .
loads on both products and all shipmentsare made on returnable pallets. SinceAcme purchases these items' for use onboth products, it has reported thequantities used on the summary sheetonly. The production of both products
increased and the purchas~ of new palletsto replace old ones stayed at a constantlevel. Acme used an adjustment factor of.82 to calculate the adjusted weight offilm and pallets, which represents arealistic level for an over3.J.1productionincrease for both products.
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53
3. Preparing a Packaging Reduction Workplan
The Packaging Audit is used to.measurethe changes in packaging use, reuse,recycling, and recycled content achievedby a company from the base year to theyear in which the audit is being carriedout. It provides an overview ofpackaging use from which a workplan canbe developed ~oreduce packaging. APaclqtging Reduction Workplanprovides information on what steps willbe taken to reduce packaging or ultimatelydivert packaging waste from disposal.
3.1 Key Features
The workplan is designed to enablecompanies to estimate the amount ofpackaging that will be used in the nexttwo-yearperiod, using the results from ,
the current packaging 'audit as a baseline.Projections are broken down into neWpackaging use avoided by reduction andreuse, and initiatives' to increase recyclingrate and reCycled content.
3.2 Sources of Data
Data for both the base year and thecurrent year can be taken directly fromthe current year's packaging audit.Projections for the next time period arebased on plans to reduce packaging, reusepackaging, institute recycling programs,improve recyclability, and increaserecycled content.
3~3 What to Include in theWorkplan
All components of the products'packaging, including primary andsecondary containers, c~osures,dispensingor applicator attachments, labels, shippingcontainers, partitions, dividers, etc.should be considered, as well as matenal
used for unitizing shipments, such as,pallets, slip sheets, shrink or stretch wrapfilln, metal or plastic strapping~ bulkcontainers, shrouds and caps. However,only those components for whIch .initiatives will be undertaken need bereported on the Workplan Worksheets.
3.4 Completing the Packaging'Reduction Workplan Forms
The packaging reduction workplan reportconsists of two forms: The PackagingReduction Workplan Worksheet, and thePackaging Reduction Workplan SummarySheet (blank sample forms can be found
. in AppendixC).
3.4.1 The Workplan Worksheet
There are four separate worksheets, oneeach for plans coveringreduction, reuse, ,
recycling, and recycledcontent. Aworksheetfor each of these initiativesshouldbe completedby materialcategory.The numbersshouldbe based on totalpackagingusedas in the audit summarysheet and not,broken down by packagetype or size as in the packagingauditworksheet. '
The Current Year and the Period
covered, together with the CompanyName should be entered at the top of the,page.
Reduction or Diversion Initiatives
Packaging Material Categories should beentered from the Packaging AuditSummary Sheet.
Weight of Material Used in CurrentYear -Totals from the Packaging AuditSummary Sheet should be transferred to
14
.....
the appropriate. packaging materialcategory in this cOlumn.
Action Taken - The planned wastereduction or diversion initiative should bebriefly describedin this column. .
Planned Reduction -Report theestimated weight of packaging wasteavoided or diverted through sourcereduction, in tonnes.
Date Implemented - This date should bethe actual date that the program was, or isto be implemented.
The forms for. reuse, recycling, aridrecycled content should be completed inthe samemanner.. .
3.4.2 The Workplan Summary Sheet
The Current Year, the Period coveredshouldbe entered at the top of the formtogetherwith the Co~pany Name and theNumber of Worksheets included..
Totals by packaging material categoryfrom each of the worksheets should beentered in the corresponding column inthe Packaging Reduction WorkplanSummary Sheet and added whereappropriate.
3.4.3 Sample Forms
The following examples show how AcmeW.rdgetsInc. prepared its workplan aftercompleting its audit for 1992. Fourworksheets have been completed, oneeach for reduction, reuse, recycling andrecycled content.
All worksheets show the Current Year aswell as the Company. Name. The
Packaging Components that Acme hasconsidered in its workplan are listed inthe left-hand column. The weight of NewMaterial Used in the Current Year istaken from the Packaging. AuditSummary Sheet. .
Worksheet #1
In Worksheet #1, the proposed actionsto.reduce the packaging are listed. Fortheir plastic bottles, Acme plans to furtherreduce the wall thickness by 15%, and itestimates that this will .save 6.76 tonnes ofmaterial, based on current productionlevels. The company anticipates havingthis in place by July 1993. No reductionis possible on plastic caps, but it is listedto indicate that this item was investigated.The company has determined that it caneliminate the overwrap, saving .32tonnes. No further reduction is possibleon the folding cartons, but Acme plans tocut back the flaps .on their corrugatedcases to achieve a 22% or 3.60 tonnesmaterial reduction.
Worksheet #2 .
Worksheet #2 shows Acme's plan to reusemore of its wood pallets so that 18 tonneswill be reused each year, i tonnes morethan in current year.
Worksheet #3
On Worksheet #3, Acme indicates that asa result of its efforts, together with otherorganizations. in the carton and paperboardindustries,by Noyember 1993folding .
cartons will be recyclable at an initial rateof 10%. . .
-I5
W orksheet #4
Worksheet #4 shows that Acme plans toincrease the recycled content in itscorrugated cases to 60% fo,rboth packagetypes. '
The Summary Sheet
The current year and period coveredare "
both shown. The audit was carried out in1992. The period is for 1992 to 1994.This means that changes should beinplac,eby 1994. The number ofworksheets attached is shown as 4.
The packaging materials are shown in theleft-hand column, and cover all thosematerials contained in the worksheets.The weight reduced has been transferredfrom the Worksheet #1, the weight reusedfrom Worksheet #2, the recycling rate istransferred from the recycling Worksheet#3, and the percentage of recycled contentfrom Worksheet #4.
16
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4. Suggestions for Developing aPackaaina Reduction Workolan
The Canadian Code of PreferredPackagmg Practices provides some broadguidelines to follow when developing aPackaging Reduction Workplan. Thispublication is available from EnvironmentCanada and Provincial EnvironmentMinistries. There is also a usefulchecklist in the appendices of the Codewhich can be used to ensure that everypossible option for pac~ging reductionhas been considered.
The following suggestions provide a basisfor the development .of a workplan, andare also to stimulate ideas for otherpackaging reduction initiatives.Suggestions are presented according to theThree R hierarchy of reduce, reuse andrecycle. Brand owners. who do notmanufacture their products can work withmanufacturers to investigate options forpackaging reduction or diversion fromdisposal. .
4. 1 Reduction
· Determine whether the package can beeliminatedentirely. As an example,some hardware items can be
. merchandisedin bins insteadof usingasleeve or backing card to hang theproduct on a pegboard.
· If the entire package cannot beeliminated, perhaps one or morepackage components can be. A goodexample of this can be seen on somebrands of toothpaste, which haveeliminated the outer carton leaving thetube to stand alone on a redesigned cap.
· It may be possibleto eliminate .secondary or tertiary packaging byincreasing primary packaging to achievea net reduction. Conversely, a
reduction in primary .packaging mightbe possible through changes tosecondary or tertiary packaging. Theimportant thing is to ensure that areduction in materials in one part of thepackage system does not lead to anincrease in materials in another part ofthe system.
· Source reduction can sometimes be
achieved by packaging geometry o~structural design changes (e.g., lowerpackaging surface area to productvolume ratios). For example, a lowprofile, cubic section carton uses lessmaterial than a taller carton with largeface panel and narrow front-to-backdimensions with the same cubiccapacity; similarly, cylindrical bottlesuse material more efficiently thanbottles with oval sections. Anotheroption to consider is reducing the sizeand use of flaps on corrugated shippingcases. Although this leaves an openingin the top and bottom of the shipper,there are many applications where thisdoes not effect the functionality of theshipper.
· Determine whether the material
thickness or basis weight can bereduced. For example, reductions maybe possible in the calliper of cardboardused to make a folding carton , the wallthickness of a glass or plastic container,or the basis weight of a label stock.
· It may be possible to reduce the overallpackaging volume by using differentpackaging materials or container typesor by using new package or producttechnology. A good example of thiskind of reduction is the pouch used asrefill containers for detergents and otherhousehold cleaners. The use of a
22
flexible pouch has resulted in significantmaterial weight savings oyer' the moreconventional plastic bottles.' In thisway, the product is made available inlightweight, smaller or concentratedrefills so that the original container canbe reused.' .
· It may be possible to change the productitself in order to reduce the amountof .
packaging,e.g., the productcould be .
cpncentrated, made less fragile, ormade in a more space-efficient shape orconfiguration.
· Source reduction can usually beachieved by replacing a number ofsmaller packages with a single larger,more efficient package size. Examplesinclude family-size or bulk containersrather than individual portion packagesand larger shipping containers.
· Changes to the transportation anddistribution processes could result inless packaging being necessary.
. · Suggestionscan be soughtfromcustomers on source reduction
possibilities for secondary and tertiarypackaging. .
· When considering the possibilities forpackage reduction~ the use of toxicmaterials should be thoroughlyreviewed. If any toxic materials areused when manufactUring packagingmaterials, check to see whether thesecan be eliminated or reduced to themiI)'imumlevel possible. For example,the use' of heavy metals in some printinginks poses a health threat during themanufacture, use and disposal of theseinks, including the disposal ofpackaging to which they may beapplied.
4.2 Reuse/Recycling
Reuse and recycling are post-use actionsintended to divert used packagingmaterials from municipal solid wastesites. Opportunities for reuse andrecycling should therefore be fullyinvestigated.
,The use of technically recyclable materialsis not an acceptable means of reducingenvironmentalimpactsunless .
economically viable collection, processingand marketing systems are available forthat material. If there is no such systemin place, but the.technology and marketexist to develop one, then all partiesinvolved should work together on itsdevelopment.
· Consider ways in' which the package orone of. its components could be designedto be safely refilled or reused by theconsumer. Several liquid cleaningproducts are .now sold in plastic bottles,some with pumps or spray attachments.These bottles are intended to be refilledfrom lighter weight bottles withoutpumps or from flexible pouches.
· Determine whether the package or oneof its components can be designed to bereusable for the same purpose withoutremanufacturing. The best ~xample ofthis application is the returnable glassbeverage bottle. Obviously there mustbe a suitable system in place, or capableof being put in place, to collect, return,and reuse these used packages.
· If current packagipg is not recyclable,determine whether it can be made to be
recyclable. Does the recycling . .
technology exist? Is there a collectionsystem in place, and is:there a mat;ket
23
for the material?
· Consider ways in which the packagecould be redesigned to make it morerecyclable. Determine whether a singlematerial can be used in place of a multi-"materialcontaineror whethera material "
that is not recyclable can be replacedwith one that is.
· Consider whether materials are suitablefor recycling. Determine the impactthat additives, coatings, inks andpigments, adhesives, labels,combinations of multi-materials, andconvenience features such as tear tapesor"carrying handles, may have on therecycling process.
· If possible, the outer and"innerpackaging used for shipment anddistribution of goods should also berecyclable.
· Reusable pallets should be used in" preferenceto the one-tripvariety, and
other ~sportation.,.related packagingshould be reusable whenever possible.
· Determine whether current packaginguses recycled material and in whatproportion. Consider ways to userecycled material or increase therecycled content level. Use of recycledmaterial in packaging materials isextremely important, since it providesthe market for recyclable materials.Refer to Consumer and CorporateAffairs Canada's Guidelines onEnvironmental Claims and Labellingif using words or symbols to relayinformation on recyclability or recycledcontent of the packaging.
24
Appendix A
Statistics Canada Packaging Material Categories
1.00 Multi-Material 2.30" Film. sheet. wrap. liners andstrapping of plastic (polymers.
1.10 Predominantly plastic by weight propylene. polyethyleneterephthalate)
1.20 Predominantly paper by weight(e.g. milk/iuice cartons. aseptic 2.40 Carboys. bottles and flasks andcartons. etc) similar articles
1.21 Milk cartons 2.50 Plastic stoppers. lids. caps and1.22 Other, predominantly paper by other closures
weight2.60 Expanded foam
1.30 Predominantly metal by weight(e.g. aerosol cans) 2.61 Foam eggtrays, trays and
containers1.31 Backed aluminum foil, of a 2.62 Foam tumblers, cups, plates,
thickness of less than 0.27 mm platters, bowls, etc.embossed not printed 2.63 Other expanded foam
1.32 Other backed aluminum foil,predominantly metal by weight 2.70 Other plastic
1.33 Other predominantly metal byweight 2.71 Other plastic packaging articles
2.72 Self adhesive plastics, width less2.00 Plastic then 20 cm
2.73 Other plastic plates, sheets, film,2.10 Boxes. cases. crates. drums. pails. foil
cups and tubes (excluding foam) 2.74 Plastic garment hangers2.75 Knotted netting of twine cordage
2.11 Egg trays, other than foam and rope of nylon, polyesters or2.12 Disposable containers of polypropylene
polystyrene (excluding foam) for 2.76 Other plasticfood
2.13. Plastic containers, tubs, pails, etc. 3.00 Woodfor food
2.14 Plastic containers, drums, cans, 3.10 Pallets. box pallets and other loadvials, pails, etc. other than for boards of woodfood
3.20 Other woods (including cases.2".20 Sacks. bags and flexible liners boxes.baskets.bins.barrelsand .
(including cones). of plastic cores)(polymers. ethylene)
25
26
3.21 Cases, boxes, crates, drums, bins, 4.60 Trays. dishes. plates. cups.barrels, cores and similar cartons. dividers of paperboardpackagings of wood and pulp
3.22 Clothes hangers3.23 Other articles of wood 4.61 Cups, food packaging of paper or3.24 Twine, cordage, ropes, and cables paperboard
of jute, sisal, etc. 4.62 Trays, dishes, plates, cups and the3.25 Other wood like of paper and paperboard
4.63 Egg cartons, trays; plates, etc. of4.00 Paper and Cardboard moulded or pressed articles of
paper pulp4.10 Corrugated cartons. boxes and 4.64 Paper pads, gift tyings, dividers,
cases etc.4.65 Other trays, dishes plates, cups,
4.11 Corrugated paper and paperboard, cartons, dividers of paperboardwhether or notperlorated and pulp
4.12 Cartons, boxes and cases ofcorrugated paper or paperboard 4.70 Labels and tags of paper
4.13 Other paper and cardboard4.80 Other paper (including record
4.20 Non-corrugated boxes. cartons and sleeves. wrappers and wrappingcases paper). kraft paper and paperboard
4.21 Folding cartons, boxes and cases 5.00 Textilesof non- corrugated paper orpaperboard 5.10 Textile sacks. bags and wrapping
4.22 Set-up boxes of non-corrugated of iute or other textile based fibrespaper or paperboard used for packaging food
4.23 Other non-corrugated boxes,cartons and cases 6.00 Glass
4.30 Sacks and bags. base width 40 cm 6.10 Clear glass containersor more
6.11 Ampoules of clear glass4.40 Sacks and bags (including cones). 6.12 Carboys, bottles, flasks, jars, etc.
base width under 40 cm . of clear glass6.13 Other clear glass containers
4.50 Drums. cans. canisters. tubes6.20 Coloured glass containers
4.51 Wood drums, cans, canistersincluding record sleeves 6.21 Ampoules of coloured glass
4.52 Wood bobbins, spools and cops 6.22 Carboys, bottles, flasks, jars, etc.and similar supports of coloured glass
4.53 Other drums, cans, canisters, tubes
.7.70
7.717.72
7.73
7.80
7.817.827.837.84
8.00
ship,pers. etc..
Stop,pers. lids. caps and otherclosures
Crown corksStoppers, lids, caps and otherclosuresOther stoppers, lids, caps andother closures -
Other metal (including strapping.wIre and industrialstaples) .
Steel strappingWire of iron or-non-aJloy steelWire of stainless steelOther metal (including strapping,wire and industrial staples)
Miscellaneous
Appendix B
.Established Recycling Rates for Packaging Materials
Important Note Relating to Recycling Rates
Recycling rates for the packaging groups outlined in Appendix A are currently under '
developme~t by the NatiQnal Task Force on Packaging. It is anticipated, that initially,only national recycling rates will be available for use in completing the Packaging Auditand Packaging Reduction Workplan. '
Preliminary national recycling rates based on development of packaging estimates for theNational Packaging Protocol baseline year of 1988 will be released by the Task Force.These rates will be finalized after the data from the 1990 and 1992 Packaging Surveys '
have been analyzed. National recycling ,rates for 1990 and 1992 should be available byAutumn 1992 and 1993, respectively. Release of these rates will be announced in theNAPP News, via a general media release and to industry associations. To obtain thelatest national recycling rates, contact your provincial, territorial or federal environmentministry (addresses provided'on the inside back cover); or the CCME Secretariat.
It is important to note that companies which manufacture products or packages for aregional/provincial market must use caution in applying national recycling rates to theirproducts due to the fact .that they may not reflect the actual amount of that company's'packages that are being recycled. ','
Over time, as reliable province-specific data become available, provincial recycling rateswill be developed that will provide a more accurate determination of the percentage of aspecific pa~kaging material that is recycled in each province. '
28
", . . . .
Packaging Audits .and Packaging Reduction W orkplans. (CCME EPC-NAPP-44E, June 1992) . .
Addendum' to AppendixB:Recycling Rates for 1988
Source: 1988 Statistics Canada Survey of Manufacturers and'estimates developed .
by the Nati~nalTask Force on Packaging .
L NIA -Data not available2. RecyclingRate = Amountrecycled .
.' New AmountUsed (doesnot include'reuse)
Notes:
July 1992
Packaging Material Category.
. Code Estimated Recycling Rate. ,
Mul-Material 1.0 N/A...
Plastic (all) . 2.0 2.0
Wood (all) 3.0 .3.2
.Paper and Cardboard 4.0
. .CorrUgated cartons 4.1 37.4'
Non-corrugated cartons 4;2 146 .
Othr . . 4.3-4.8 N/A
Textiles 5.0 NIA .
Glass (all) 6.0 6.4
Metal (exceptaluminum) 7.1-7.4 4.87.7-7.8
Aluminum 7.5-7.6 42.4
Packaging Audits and Packaging Reduction Workplans(CCME EPC-NAPP-44E, June 1992)
Addendum to Appen~ix B: Recy.cling Rates for 1992
. .
Source:. . 1992 Statistics Canada National Packaging Survey and National PackagingMoIiitoring System . .'
Notes: 1. 'Packaging Material Categories and Codes from Appendix A
2. RecyclingRate = Amountrecycled .
New Amount Used (does not include..reuse)July 1994
Packaging Material Category Code! EstimatedRecyclingRate2(%)
Multi-Material 1.0-1.3 1
Plastic
Boxes, caSes, crates, drums, pails, cups & tubes (excluding foam) 2.1. 34
Sacks, bags, flexible liners, plaStic film, sheet, wrap & strapping. . 2.2-2.3 4
Carboys, bottles & flasks 2.4 14
Other plastic packaging 2.5-2.7 5
Wood
Wood:pallets, box pallets & other wood load boards 3.1 8
Other wood packaging (cases, boxes, bins barrels, cores) 3.2 . . 3
Paper and Paperoard
Corrugated cartons. . 4.1 64
Non-corrugated cartons 4.2 39
Other paper packaging 4.3-4.8 20
Textiles 5.1 1
Glass 6.1-6.2 37
FerroUs & Non-ferrous Metal -
Metal food and bc::veragecontainers 7.1,7.5 49,
Other metal packaging 7.27.4 557.6-7.8
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For more information, please contact:
Canadian Council of Ministers of .theEnvironment .
326 Broadway,. Su!te 400Winnipeg, Manitoba.R3C OS5 .
Office of Waste Management'Environ~ent C~adaOttawa, OntarioK1A OH3
Environmental Protection Division
B.~. Ministry of Environment, Lands andParks ..
3rd Floor~ 777 Broughton Street.Victoria, BritishColumbiaV8V 1X5
PublicationsAlbertaEnvironment .
14th Floor, 9820-106 StreetEdmonton, AlbertaT5K 216
Policy.arid .Planning Branch .Yukon Department of Renewable Resources10 Bums Street, P.O. Box 2703~itehorse, Yukon
. .Y1A 2C6
Pollution Control Division. NorthwestTerritories RenewableResources
P'.O. Box 1320 ..6th Floor, CourthouseYellowknife, Northwest TerritoriesX1A 2L9
Sa,skatchewanEnvironment and Pub~icSafety .
Walter Scott Building3085 Albert StreetRegina, SaskatchewanS4S OB1
Waste Reducti-onand Prevention Branch
Manitoba Departnient"of the Environmen~960-330 S1. Mary AvenueWinnipeg, ManitobaR3C 3Z5 .
Waste Reduction Office
Ontario Ministry of the Environment40 S1. Clair Avenue WestToronto, OntarioM4V 1M2. .
Direction de la recuperation et du recyc1ageMinistere de I'Environnement du Quebec2360 Sainte-Foy Street, 1st FloorSainte-Foy, QuebecG1V 4H2 ..
Solid Waste and Recycling SectionNew Brunswick EnvironmentP.O. Box 6000Fredericton, New BrunswickE3B 5H1
Municipal Waste and Resource RecoveryNova Scotia Department of the .Environmen~ .P.O. Box 2107Halifax, Nova SconaB3J 3B7
Environmental Protection Division
P .E.I. Department of the Environment11 Kent Street, P.O. Box 2000. .Charlottetown, Prince Edward IslandCIA ?N8
Licensing and EnforcementNewfoundland Environment and LandsP.O. Box 8700, 4th FloorConfederation Building., West }~lock5.1.John's, NewfoundlandA1B 416
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