Plastics in PackagingPlastics in Packaging

Scott H. BoyleBrian D’AmicoJanine HornMark Przybylski

What Will be DiscussedWhat Will be Discussed

Definition of a plastic.Overview of the packaging industry.Why plastics are used in packaging.A detailed look at the different types of

plastics used in packaging.How plastics compare to alternative

materials.Environmental Impacts

What is a Plastic?What is a Plastic?

A plastic is defined as an organic material that has the ability to flow into a desired shape when heat and pressure are applied and to retain that shape when they are withdrawn.

Composed primarily of a binder with-• Plasticizers

• Fillers

• Pigments

• Other additives

Industry OverviewIndustry Overview

World sales of primary packaging materials estimated to be $434 billion in 2001.

• Up 12.5% from $385 billion in 1997.

World sales of finished packaging materials is estimated to be $800 billion.

Four main categories of raw packaging materials:• Paper and Board• Glass• Metal• Plastic

Over the past few years, plastic has become increasingly popular.

Why Plastics?Why Plastics?

A wide variety of different qualities-– Rigid vs. Flexible

– Clear vs. Opaque

LightweightStrongCost

Which Plastics are Used?Which Plastics are Used?

Six resins account for almost 97 percent of all plastic used in packaging.

Polyethylene terephthalate (PET) – 9% High-density polyethylene (HDPE) – 29% Low-density polyethylene (LDPE) – 32% Poly-vinyl chloride (PVC) – 5% Poly-propylene (PP) – 11% Polystyrene (PS) – 11%

PolypropylenePolypropylene

Physical Properties– Durable

High elongation– 300%

High Tensile Strength – 4500 psi

High Yield Strength – 4000 psi

– High Melting point– Low Density

Lowest density of all plastics used in packaging

Why Polypropylene?Why Polypropylene?

Practicality – Inexpensive– Chemically resistant– Ideal for holding hot liquids– Stretchy vs. rigid

Many everyday uses– Ketchup bottles– Peanut butter jars

Polyvinyl ChloridePolyvinyl Chloride

Need Title Chemically non-reactive Flexible vs. Rigid Self Extinguishing Plasticized vs. Unplasticized

– Plasticized is more flexible

Why PVCWhy PVC

Versatile– Can be machined with standard metal working tools

Self Extinguishing– Used to house electrical wiring

Many forms– Sheet– Tubing– Piping

Polyvinylidene DichloridePolyvinylidene Dichloride

Discovered in 1933– Accidental Discovery– Original use was to stop corrosion on airplanes– After a green color and a pungent smell had

been removed it was used for food storage.

Most common form of PVDC is Saran Wrap®

Why PVDCWhy PVDC

PVDC is a very effective food preservation method.– Co-polymerization used in synthesis creates a

very tight molecular chain Provides good barrier against air and moisture.

Chemically non-reactive– Ensures that food won’t taste like plastic

Plastic vs. The AlternativesPlastic vs. The AlternativesStress StrengthsStress Strengths

100

550

30

1000

50100

19 25

0

200

400

600

800

1000

Stress Strength (MPa)

AluminumAlloy

Glass Wood(Oak)

Plastic(PE)

Material

Stress Strengths of Packaging Materials

Minimum

Maximum

Plastic vs. The AlternativesPlastic vs. The Alternatives Incredibly lightweight

2 lbs of plastic can deliver 1000 oz. of liquid. To carry the same amount it would take:

• 3 lbs of aluminum

• 8 lbs of steel

• 27 lbs of glass

Compared to glass, plastic drink bottles allow a distribution truck to carry up to 63% more drink and 83% less packaging.

Compared to paper, 7 trucks are needed to deliver the same quantity of paper bags contained in one truckload of plastic bags.

Plastic vs. The AlternativesPlastic vs. The Alternatives

Cost As of mid-2000, PET was selling for app. $.62/lb. Around the same time, aluminum alloy was selling

for app. $1.28/lb.

– Plastic reduces distribution costs-• Decrease in necessary truckloads

• Fuel savings

– Reduces lost inventory costs.

Plastic vs. The AlternativesPlastic vs. The AlternativesEnvironment Impact

Plastics are recycled less frequently than glass and aluminum.

Plastics are not biodegradable.

Plastic vs. The AlternativesPlastic vs. The AlternativesEnvironmental Impact

Plastic also has a positive impact on the environment. Consider the following fact:

– When comparing the manufacturing processes of polystyrene and paper cups, it was found the the paper cups use:

• 15 times more chemicals.

• More than 6 times more steam.

• 13 times more electricity.

• 30% more cooling water.

• 170 times more process water.

The lightweight nature of plastics results in fewer truckloads and less fuel usage.

Recycle (cont.)Recycle (cont.)

Recycling process– Collection– Sorting– Reclamation

Recycle (cont.)Recycle (cont.)

Benefits– Less landfill waste– Environmentally friendly

RecycleRecycle

Statistics– >80% of all US households have access to plastic

collection and recycling programs– In 1998 plastic bottle packaging amassed 1.45 billion

pounds by volume

Commonly recycled plastics– Plastic Grocery Bags– Plastic Milk Jugs and Detergent Bottles– Plastic Beverage Containers

Reuse (cont.)Reuse (cont.)

Good Examples– Large reusable containers

Small packages of concentrated product are bought and diluted to large container

Reduces product packaging cost, landfill space

– Reusable Plastic Shipping Containers (RPSC’s) Replaces single use containers Reduces shipping/receiving costs, landfill space

Reusing and Recycling Plastic Reusing and Recycling Plastic PackagingPackaging

Reuse– Statistics– Commonly reused plastic packaging– Benefits– Good Examples

Recycle– Statistics– Commonly recycled plastic packaging– Recycling Process– Benefits

ReuseReuse

Statistic– A 1997 survey found 80% of Americans reuse

plastic products and packaging

Common Reusable Packaging– Plastic Grocery Bags– Plastic Milk Jugs and Detergent Bottles– Plastic Beverage Containers

Reuse (cont.)Reuse (cont.)

Benefits– Good Properties

Long lasting Durable Chemically inert

– Delays filling of landfills– Lowers cost of garbage disposal

In SummaryIn Summary

Plastics

– Lighter …..…………………………….

– Cheaper …………...

– More Durable ………………………

Questions???Questions???