Businesses and institutions are in a powerful position to reduce packaging wastes and save money. Businesses can influence supplier contract terms toward environmentally preferable packaging practices, and other "green" contract related issues. Most businesses can significantly reduce the amount of packaging on their products, demonstrating concern about the environment to customers. In some cases, federal and state laws (e.g., California's Rigid Plastic Container Packaging Law), impose new environmental requirements and taxes on many packaged products.¹

Manufacturers may receive parts and materials from many different vendors worldwide. Waste reduction opportunities for manufacturing facilities include reducing the packaging used for items received from suppliers and items shipped to warehouses and retailers. The amount of packaging used to protect parts and materials from damage during shipment and storage is sometimes excessive.

Packaging reduction can have a significant impact on a facility's waste generation. Typically, the majority of solid waste generated by a manufacturing business is related to packaging. Reduced packaging leads to cost savings for purchased parts, product shipment, and waste disposal. Also, the use of recycled content materials "closes the loop" on recycling, and helps to maintain viable markets for recyclable materials in the future.

Recommendations:

Develop standard contract language with suppliers to address the following issues:

• Minimize the amount of packaging used for transporting materials to/from facilities.

• Require the use of recycled-content packaging.

• Require the use of reusable boxes and pallets.

Small businesses could get help from trade associations who may be able to provide assistance by approaching suppliers about these issues on behalf of a large number of facilities.

Common examples of excessive packaging which should be addressed include:

• Plastic bags, cardboard separators, and foam padding or styrofoam peanuts used for packing non-cosmetic parts. Non-cosmetic parts can frequently be shipped in bulk (without individual packaging) because slight scratching would not impact quality.

• Padded bags with tied plastic wrap or plastic/wire closures. The closures often use more material than is necessary. No tie-wrap may be required if the container is designed correctly.

• Redundant packaging. A good example is boxes shipped inside other boxes.

Manufacturers can request certain types of packaging from suppliers. They also can consider waste reduction when repackaging items for sale to customers. Manufacturers should review all packaging specifications for redundancy and develop a policy that reviews potential solid waste impacts of new packaging requirements. The following ideas may help get you started.

• Reduce multiple layers of packaging whenever product integrity will not be threatened. For instance, wrapping smaller boxes on a pallet or in reusable trays or totes (without a larger box as a container) can reduce packaging waste and save money.

• Include packaging questions in market research surveys in order to evaluate consumer preferences regarding packaging. More and more consumers are choosing products packaged in minimal amounts of materials.

• Investigate the use of fiberboard trays and stretch wrap. Large wholesalers commonly ship materials to warehouse clubs (i.e., Sam's, BJs, Pace, Price Club) using specialized packages of only stretch wrapped fiberboard trays rather than cardboard boxes, reducing corrugated cardboard waste by over 25 percent. This approach could possibly be used by smaller manufacturers and retailers.

• Coordinate packaging reduction efforts with suppliers and customers. Potential cost savings may be achievable from reduced purchasing requirements, lower labor and disposal costs for the supplier, the manufacturer, the retailer, and the customer. Work with suppliers and customers to brainstorm packaging reduction ideas and promote "green packaging.

• Buy packaging and other products made with recycled-content materials. Contract language for suppliers of parts and packaging materials should be modified to specify recycled content levels. See the fact sheet on "Developing a Facility-Specific Affirmative Procurement Project" for information on vendors that sell products with recycled content.

• Encourage suppliers to design for recycling. The design of a product or packaging system should take into account the "recyclability" of the item after its useful life is completed. For example, if multiple plastic parts are used in a product design, the plastic would be easier to recycle if it was all made from the same type material. Mixtures of different type plastics create problems for segregating properly.

• Another design to avoid, for example, is packaging that uses cardboard bonded to styrofoam (or urethane foam). This is because it creates a segregation problem for recyclers making it less likely to be recycled. Contracts should direct suppliers to use more recyclable designs and materials.

The implementation and success of many waste reduction opportunities depends on cooperation between suppliers, manufacturers, and retailers. If the retailers do not want to alter packaging, the manufacturer may not have any choice in reducing or altering packaging.

Packaging is meant to reduce damage of goods. Packaging waste reduction efforts must not compromise the package function.

Recycled content packaging may cost more than virgin materials. Increased costs resulting from the use of recycled content materials may not be well received by customers and retailers. All requirements for packaging changes should be carefully researched before implementation.

¹ California's Rigid Plastic Packaging Container Program requires that most rigid plastic containers with a volume greater than eight ounces: a) be made from recycled materials, b) be reduced in weight by ten percent, c) or meet recycling goals. This law applies to products sold in California. Mexico has just enacted legislation that requires resin coding on certain plastic containers. The European Union has adopted the Directive on Packaging and Packaging Waste, requiring each member state to meet specific five and ten-year goals. Germany, Italy, France, Austria and Hungary have levied material-specific fees on packaing. Other members are rapidly following suit. Japan's Bill Concerning Promotion of Separation, Collection and Recycling of Container Packaging will require businesses to recycle packaging wastes. Producers of plastic containers and paperboard packaging will be required to ensure the recovery of these materials. (SOURCE: SAIC)