The Green Bottle sources paper and plastic bottles that are molded into any shape. Details can be printed directly onto the bottle, style is within the branding, however primary colour is green to push the green aspect even further.
Friday, 4 January 2013
Bottle Label and Refill Bottle
Tuesday, 27 November 2012
Development
The development of my prototype had to be completely re thought to successfully continue forward. This became apparent after discussing the prototype with learning teams and with the lecturer.
After peer reviews it became obvious that the actual concept would not work. You need to empty the bottle to use it as a measuring utensil for the recipe. However you can't put any worcestershire sauce into your meal since it has all been used!
As well as this asking the customer to cut the bottle creates a whole new type of problem. Customers want things made as easy as possible and asking them to make a the measuring jug with 3 different work processes only explained in info graphics makes the task unreasonable.
I also had a problem with fixing the label on. Glue needs to be applied on BOTH sides so that once reversed, the label wont be loose and hard to use as a measuring tool. It is impossible to add glue to the outside of the label as it would get dirty and unusable very quickly. Adding a plastic cover that can be removed only adds more production processes and will only hinder the costing and environmental impact rather then help.
The concept needs to be completely developed. However I would still like to keep the iconic strip that goes over the neck, back and front that was the same as my original design.
I went back to square one and looked at inventive wine bottle labels.
http://scarletbits.com/2009/creative-inspiration-from-bottle-labels/
- this gave me some ideas to how to counteract the placement of the reversible label and how to fixate this to the bottle.
- i also re looked at how bottles can be re used in general to spark and different multi use ideas.
http://www.favecrafts.com/Wine-Bottle-Crafts/10-Things-to-Do-With-Old-Wine-Bottles#
I have also looked at GREEN products such as 'Innocent Smoothies' and through research realised a couple of important new factors that will ultimately change my original PLA plastic bottle.
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After peer reviews it became obvious that the actual concept would not work. You need to empty the bottle to use it as a measuring utensil for the recipe. However you can't put any worcestershire sauce into your meal since it has all been used!
As well as this asking the customer to cut the bottle creates a whole new type of problem. Customers want things made as easy as possible and asking them to make a the measuring jug with 3 different work processes only explained in info graphics makes the task unreasonable.
I also had a problem with fixing the label on. Glue needs to be applied on BOTH sides so that once reversed, the label wont be loose and hard to use as a measuring tool. It is impossible to add glue to the outside of the label as it would get dirty and unusable very quickly. Adding a plastic cover that can be removed only adds more production processes and will only hinder the costing and environmental impact rather then help.
The concept needs to be completely developed. However I would still like to keep the iconic strip that goes over the neck, back and front that was the same as my original design.
I went back to square one and looked at inventive wine bottle labels.
http://scarletbits.com/2009/creative-inspiration-from-bottle-labels/
- this gave me some ideas to how to counteract the placement of the reversible label and how to fixate this to the bottle.
- i also re looked at how bottles can be re used in general to spark and different multi use ideas.
http://www.favecrafts.com/Wine-Bottle-Crafts/10-Things-to-Do-With-Old-Wine-Bottles#
I have also looked at GREEN products such as 'Innocent Smoothies' and through research realised a couple of important new factors that will ultimately change my original PLA plastic bottle.
The innocent smoothie range hold fresh
blended fruit. The packaging needs to uphold their environmental campaign and
be safe to store the drink.
They experimented with PLA (derived from
corn) but decided 100% PCR bottles where more sustainable – ‘composting is not
yet a mainstream end of life option here in the UK, with only 5% of households
collect food waste’ So instead introduced a 100% recycled bottle. Most UK
households have a plastic recycle collection then biodegradable waste collection. Innocent
smoothies
altered the caps on their bottles which meant saying 20 tonnes
of plastic each year, which means that the non-renewal source of oil that is
being used to make the plastic is being saved!
2000 – Reducing waste
Coca‑Cola introduced the ultra-glass contour bottle designed for improved impact resistance, reduced weight and cost. These bottles are 40 per cent stronger and 20 per cent lighter than the original Coca‑Cola contour bottle – saving approximately 52,000 metric tons of glass in 2006.
Coke has reduced the weight of its 330ml Contour bottle, first developed in 1916, by 20% from 263g to 210g to create the new Ultra bottle.
The company has also expanded the bottle's width by 0.1mm and reduced its height by 13mm.
Ardagh Glass will provide the drinks giant with 67 million Ultra bottles per year.
THE BENEFITS OF GLASS RECYCLING
- Glass can be recycled over and over again.
- Separating and recycling glass could significantly reduce waste management costs.
- Landfill tax will double by 2009, furthering increasing disposal costs.
Every year, the average British family consumes around 500 glass bottles or jars. There are good reasons why these bottles and jars should all be recycled.
The amount of energy needed to melt recycled glass is considerably less than that needed to melt raw materials to make new bottles and jars. Recycling one bottle can save enough energy to power a television set for one and a half hours.
Not only does glass save energy by using recycled glass, but each 1000 tonnes of recycled glass that we melt saves 314 tonnes of CO2 per.
Using recycled glass in furnaces saves hundreds of thousands of tonnes of primary raw materials each year. This reduces the need for quarrying raw materials and conserves the countryside.
Every tonne of glass recycled extends the life of our increasingly scarce landfill sites and conserves the British countryside
In terms of weight, glass makes up about 8% of the household waste stream. Any increase in the amount of glass recycled means savings on waste collection and disposal costs, which are increasing due to landfill tax.
Every individual can play an active part in conservation by simply supporting glass recycling. This is the first step to becoming an environmentally active consumer.
Estimates indicate that 500 jobs are created for every 100,000 tonnes of glass collected for recycling. Recycling all the glass we currently throw away would create 7500 new jobs.
For the reasons above and the fact that the UK doesn't have the processing power to safely dispose of PLA products (as well as the public knowledge of how to dispose of the product is minimal still) i have decided to stay with a thinner, recycled glass. As I am changing the concept anyway I can re think of how to use the label without cutting the bottle.
Some new concept sketches
I will also look into changing the bottle cap, making it a twist and release cap with a membrane across the top that only releases droplets of sauce at a time. I would like to make it removable so each part can be easily recycled.
My first thought was to physically SHOW the client that the label material was recycled paper by keeping it raw paper grains and not printing all over it to hide the paper. I think this makes the product look high quality and an obvious indication of environmentally friendly materials.
This is my first draft that i came up with. I made a character wearing the royal crest (has to be included from the brief) pouring worcester sauce onto the label. I mention L&P on the character however i wanted to emphasise the original and genuine, to grab peoples attention and play on the strong brand awareness that L&P already has.
This label TUCKS into a cut slot on another label that runs around the base of the bottle. This is makes it so that the main label can be pulled out, reversed, then slot back in without using glue.
However, the use of a character may alienate the older market, by making it more flexible to the customers I could make a more neutral version. eg.
1.The front removes the character and places the crown with a simple L&P centralised top. It will increase production costs to get the liquid blobs die cut so i was going to make these printed out of green inks. The simple 'Original & Genuine' is the focal point of this label, with the classic orange. I also added a moving slogan ' one little drop can make one great big taste'. The idea of this is to MAKE it personal, through language and design. I believe this will more strongly appeal to a younger audience, however has an obvious environmentally friendly look and interesting labelling which should attract the eco-buyer.
Such examples where playful language has been used successfully is 'Innocent Smoothie' and 'Aussie Hair Products'.
A small arrow with 'Pull' indicates that you must pull the label out of the slot, front and back.
2. The back of the label explains how to use it, pull it out and reverse the label for the recipe. I wanted to make sure people new a green product was being pushed so i created a perforated section (easy to produce in factories) with L&P GOES GREEN as a statement, similar to the design on the front, keeping continuity. This perforated section has ANOTHER use however. This section can be ripped off the label very easily and has the voucher offer on the reverse side. The voucher details is on the reverse side so that people wont know straight away and knick them to gain the benefits.
3. On the reverse side the offer becomes realised. It is a one time use only voucher that is scanned at the till with your refill bag next time you get your shopping. With this you get a 30% discount on a refill bag made from very little packaging, this has an easy pour lid that puts the liquid back into the bottle and the refill bag can then be completely recycled. This halves the chance of buying TWO glass bottles when only one is needed.
Discount prices are negotiable with L&P and offer is only subject to availability.
To bring this design into the modern day I made a QR code that sent people straight to the website. From there they can look up a whole bunch of recipes that cant fit on the label. The website address is also added for those without smart phones.
4. This is the main recipe, the design reflects the front of the label but instead of worcester sauce it is the chosen recipe, Spaghetti Bolognese. A illustrated graphic represents this with the affect of worcester sauce being dripped into it, this flows around the recipe.
Monday, 19 November 2012
Initial Ideas and Prototype
My initial ideas above: Reducing packaging by keeping it one sided and creating a pull out alternative with further information. Explored vinyl stickers of just the company name, minimalist approach.
First started to explore the single strip idea that wraps around the top of the bottle and attached at the front. Inspired by wine bottle packaging.
First Draft
 |
| Circle has removable adhesive which is stuck onto bottle, label wraps around the lid then tucked back under the circle |
 |
| View from the front, simple, modern iconic label look. |
 |
| Side view, looks good visually. |
Design for the first prototype, label is removable and fold out to create a measuring label to create recipes using the L&P bottle.
When making the prototype a few problems occurred. When the label is unfolded (because the label wraps around the lid it is very long) it was too long for the bottle so could not accurately be used as a measuring tool and a hassle to undo.
Second Draft
 |
| Front goes straight to the bottom in an iconic strip. When this is reversed so the multi use measuring label goes from the bottom of the bottle to before the bottle curves. |
Slightly more developed design using proper identification, weight, environmental logos, websites etc. Recipe for specific meal is on the back. There can be a range of different recipe labels that can be collected so the consumer has a new recipe they can use their L&P bottle to make. Makes them hold onto it, however if they dont want to the bottle and label is completely biodegradable. Orange and black used throughout. PLA plastic bottle makes it possible to cut along the dotted line. The iconic shape will stay the same.
Info graphics showing how the bottle can be turned into a measuring jug.
How to use me:
Cut the bottle on the dotted line. Turn the neck of the bottle upside down to create the funnel.
Place the neck back through the reversed label and tuck it under the bottle.
Poor the ingrediants to the marked measurement lines to make the yummy recipe.
Save and collect L&P recipes.
Packaging & Label Material
Packaging
http://www.londonbiopackaging.com/about-our-products/eco-label-guide/
http://www.biopac.co.uk/sustainable-materials-we-use.htm
http://environment.about.com/od/greenlivingdesign/a/pla.htm
PROS AND CONS OF PLA
Dear EarthTalk: What are the environmental pros and cons of corn-based plastic as an alternative to conventional petroleum-based plastic? -- Laura McInnes, Glasgow, Scotland
http://www.londonbiopackaging.com/about-our-products/eco-label-guide/
http://www.biopac.co.uk/sustainable-materials-we-use.htm
http://environment.about.com/od/greenlivingdesign/a/pla.htm
PROS AND CONS OF PLA
Dear EarthTalk: What are the environmental pros and cons of corn-based plastic as an alternative to conventional petroleum-based plastic? -- Laura McInnes, Glasgow, Scotland
Polylactic acid (PLA), a plastic substitute made from fermented plant starch (usually corn) is quickly becoming a popular alternative to traditional petroleum-based plastics. As more and more countries and states follow the lead of China, Ireland, South Africa, Uganda and San Francisco in banning plastic grocery bags responsible for so much so-called “white pollution” around the world, PLA is poised to play a big role as a viable, biodegradable replacement.
PLA Helps to Reduce Greenhouse Gas Emissions
Proponents also tout the use of PLA—which is technically “carbon neutral” in that it comes from renewable, carbon-absorbing plants—as yet another way to reduce our emissions of greenhouse gases in a quickly warming world. PLA also will not emit toxic fumes when incinerated.
Proponents also tout the use of PLA—which is technically “carbon neutral” in that it comes from renewable, carbon-absorbing plants—as yet another way to reduce our emissions of greenhouse gases in a quickly warming world. PLA also will not emit toxic fumes when incinerated.
PLA Biodegrades Slowly Unless Subjected to Industrial Composting
But critics say that PLA is far from a panacea for dealing with the world’s plastic waste problem. For one thing, although PLA does biodegrade, it does so very slowly.
But critics say that PLA is far from a panacea for dealing with the world’s plastic waste problem. For one thing, although PLA does biodegrade, it does so very slowly.
According to Elizabeth Royte, writing in Smithsonian, PLA may well break down into its constituent parts (carbon dioxide and water) within three months in a “controlled composting environment,” that is, an industrial composting facility heated to 140 degrees Fahrenheit and fed a steady diet of digestive microbes. But it will take far longer in a compost bin, or in a landfill packed so tightly that no light and little oxygen are available to assist in the process. Indeed, analysts estimate that a PLA bottle could take anywhere from 100 to 1,000 years to decompose in a landfill.
Recyclers Can’t Mix PLA and Other Plastics
Another issue with PLA is that, because it is of different origin than regular plastic, it must be kept separate when recycled, lest it contaminate the recycling stream. Being plant-based, PLA needs to head to a composting facility, not a recycling facility, per se, when it has out served its usefulness. And that points to another problem: There are currently only 113 industrial-grade composting facilities across the United States.
Another issue with PLA is that, because it is of different origin than regular plastic, it must be kept separate when recycled, lest it contaminate the recycling stream. Being plant-based, PLA needs to head to a composting facility, not a recycling facility, per se, when it has out served its usefulness. And that points to another problem: There are currently only 113 industrial-grade composting facilities across the United States.
Most PLA Uses Genetically Modified Corn
Another downside of PLA is that it is typically made from genetically modified corn, at least in the United States. The largest producer of PLA in the world is NatureWorks, a subsidiary of Cargill, which is the world’s largest provider of genetically modified corn seed.
Another downside of PLA is that it is typically made from genetically modified corn, at least in the United States. The largest producer of PLA in the world is NatureWorks, a subsidiary of Cargill, which is the world’s largest provider of genetically modified corn seed.
With increasing demand for corn to make ethanol fuel, let alone PLA, it’s no wonder that Cargill and others have been tampering with genes to produce higher yields. But the future costs of genetic modification to the environment and human health are still largely unknown and could be very high.
Green-Minded Consumers May Prefer Alternatives to Plastics
While PLA has promise as an alternative to conventional plastic once the means of disposal are worked out, consumers might be better served by simply switching to reusable containers—from cloth bags, baskets and backpacks for grocery shopping (most chains now sell canvas bags for less than a dollar apiece) to safe, reusable (non-plastic) bottles for beverages.
While PLA has promise as an alternative to conventional plastic once the means of disposal are worked out, consumers might be better served by simply switching to reusable containers—from cloth bags, baskets and backpacks for grocery shopping (most chains now sell canvas bags for less than a dollar apiece) to safe, reusable (non-plastic) bottles for beverages.
Despite Problems, PLA Has Many Uses
As for other types of PLA items—such as those plastic “clamshells” that hold cut fruit (and there is a whole host of industrial and medical products now made from PLA)—there is no reason to pass them by. But until the kinks are worked out on the disposal and reprocessing end, PLA may not be much better than the plain old plastic it’s designed to make obsolete.
As for other types of PLA items—such as those plastic “clamshells” that hold cut fruit (and there is a whole host of industrial and medical products now made from PLA)—there is no reason to pass them by. But until the kinks are worked out on the disposal and reprocessing end, PLA may not be much better than the plain old plastic it’s designed to make obsolete.
LABEL
Robert Horne's sustainable board/paper suppliers in Northampton
60% of our landfill problems are due directly to the paper industry here in the USA. We are landfilling our waste paper or having it incinerated at a terrific cost to our pocket books and "our health". The landfills leak toxic wastes and the incinerator plants emit VOC'S (Volatile Organic Compounds) into the atmosphere.
There is no reason not to use recycled papers. They print as well as virgin papers, work well on laser printers, and can divert millions of pounds of printed waste away from the landfills and back into the mainstream.
Recycled papers save our valuable natural resources, save energy, save our trees, create less toxic bi-products, and help our over-crowded landfills.
Using recycled papers with the highest percentage of post-consumer content helps even more.
The government mandates 20% post-consumer recycled fiber to be considered recycled, but I would like to see that percentage increased, as that amount barely makes a dent into our problems. We should be looking to increase to 50% by the turn of the century.
The question of prices of the paper comes up, but what does incineration cost, what is the price of landfilling cost, and what are the medical costs to ourselves and our pocketbook? Certainly we pay for it in increased taxes and our quality of life. The paper mills can make recycled papers at lower prices as the demand for recycled papers goes up.
Using 100% post-consumer recycled papers and less bleaching agents also means less chlorine and that is the next major issue to creating a healthier atmosphere to live in. Chlorine causes Dioxin which, when mixed with other compounds, causes cancer. What is that cost to our medical bills and to ourselves?
Tree Free papers, although not considered recycled, are now considered environmentally preferable products, because they save our natural resources, use less energy in separating the lignin (the natural occuring bonding agent) from the fiber, are processed chlorine-free, and in the case of Kenaf, are pesticide-free. Tree Free plants grow in as little as 10 weeks, unlike trees that grow from 7 years to 20 years.
Example of tree free paper : http://treefreepaper.com/shop.php
ADHESIVE
In the course of their life cycle, beverage bottles can encounter a whole range of conditions – in bottle cellars, in beverage retailing, during transport, in refrigerators or during cleaning. The same applies to their labels that position the brand and also inform the consumer about the beverage’s composition and ingredients. The label is also exposed to a large variety of influences, e.g. fluctuating temperatures, changes of air, moisture and mechanical stress. The adhesives employed therefore have to do far more than just stick the label to the container. In fact, they have to feature a broad profile of processing and in-use properties. For instance, the label should not become detached from the bottle on exposure to condensation but still come off cleanly when the bottle is washed in preparation for re-use.
Sustainability as a market trendLabeling adhesives have been consistently optimized over the past few years with the goal of leaving established processes at beverage bottling plants unchanged while offering extra functional advantages. The trend toward sustainability has been making a lasting impression on the market here, as well. The growing environmental awareness of consumers and also of beverage bottlers has stimulated further demand for environmentally compatible production processes and products. Demonstrating entrepreneurial responsibility in its bid to efficiently satisfy consumer needs, the industry is investing heavily in application-driven research and development. It aspires to continuous improvement and innovative, sustainable solutions that open up new opportunities. Many companies have a traditional commitment to products based on renewable raw materials like casein and special starches. The beverage industry, for instance, often uses water-based casein adhesives to label glass containers.
The rising cost of renewable resourcesDespite their proven properties, such adhesives have their constraints. Renewable raw materials are subject to strong price fluctuations, and manufacturers are often confronted with rising costs due to increasing demand coupled with supply volatility. For example, seasonal effects and climate changes can impact on the available quantities of the derived renewable raw materials. Markets also tend to respond in a volatile and speculative manner to fluctuations in the supply situation. The price of casein, for example, has soared in the last few years – and experts anticipate that this trend will continue. Constantly rising prices for casein – a raw material derived from cow’s milk – have also driven up the cost of conventional labeling adhesives.
Always the right product for trouble-free production processesFor many years now, both beverage manufacturers, such as breweries and mineral water bottlers, and adhesives manufacturers have therefore been looking into alternative substances that are less susceptible to price fluctuations, whose performance features contribute to environmentally compatible processes and whose low complexity facilitates ease of processing. Casein-free adhesives are therefore being increasingly used, as they offer not only a longer shelf life and temperature stability, but also a whole series of further advantages over conventional labeling adhesives. These novel products based on robust polymers feature exceptionally good initial tack, for example, while supporting fast setting and drying, thus helping to reduce adhesive usage rates. They represent an effective alternative to products based on traditional resources and make it possible to save up to 30 percent on adhesives. For the industry, this expansion of the range of adhesives means greater production and budgeting security. This becomes all the more important when one considers that natural polymers may become scarce and the market situation can quickly change. With this extended range of options in adhesives, bottlers can thus make choices that cut their costs and ensure trouble-free production processes.
Tough requirementsHowever, anyone considering a switch to casein-free labeling adhesives should bear in mind a number of points when assessing the possible overall costs and the most suitable adhesive. These include the volume of waste and resource availability along with storage life and waste water treatment. The adhesive should be able to withstand wide-ranging conditions without showing any changes in its product characteristics. At the same time, it should be versatile in order to cover a broad range of labeling applications, have a neutral odor, ensure rapid drying and not disrupt the cleaning cycles of labeling machines. Furthermore, the adhesive should support the beverage bottler in his efforts to boost the efficiency of his plant by reducing the consumption of cleaning agents, additives, water and energy – and hence the production costs. These tough requirements are fully satisfied by Henkel’s improved generation of casein-free labeling adhesives.
Innovative and casein-free – performance without constraintsA number of demanding challenges have to be mastered, particularly in the returnable bottle sector. For example, it has to be possible to wash off the label during the defined cleaning process. Foaming in bottle cleaning machines has to be restricted, which today still often means high levels of defoaming agents during the wash-off process. The adhesives industry has been investigating effective solutions to these problems for some time now. As the leading supplier of adhesives technologies, Henkel embarked on the development of casein-free adhesives with equivalent bonding and processing characteristics back in the late 1990s. With its second generation of casein-free adhesives, the company now has a product series for glass bottle labeling that has a broader and more comprehensive performance spectrum and can be deservedly termed a pioneering, landmark innovation. Long-term tests have shown that the Optal XP product line meets these high customer expectations. In addition to their excellent wet tack, the adhesives exhibit good adhesion even to chilled glass surfaces. The food and beverage industry can therefore turn to a powerful and efficient range of products that cover the entire spectrum of bottle labeling needs, including sophisticated adhesive solutions with high ice-water and condensation-water resistance.
Economic and ecological process benefitsUnlike their conventional counterparts, these adhesives are based on synthetic polymers and are hence independent of the dairy industry. The raw materials employed are thus subject to lower price volatility than casein. For bottling plants, greater price stability means improved cost estimation security in their budgeting. The elimination of casein also yields further benefits, as this resource then becomes available for food production instead of being processed for technical purposes.
The use of Optal XP adhesives yields economic and ecological process benefits in terms of mileage and their field-proven wash-off behavior. Long-term use by various national and international beverage bottlers has shown that the labels can be detached with ease in bottle washing plants using standard cleaners and settings (see illustration 2). In addition, these second-generation adhesives give no cause for concern during waste water treatment. The products also have FDA approval, are free of toxic ingredients and contain no alkylphenol ethoxylates, zinc or borax.
With their outstanding machinability properties and greater efficiency in production due to improved processes and reduced complexity, the adhesives contribute to environmentally compatible production and thus offer bottling plants an equivalent alternative adhesive that is not formulated with resources from the food sector.
Ideal product design with added valueThe new generation of casein-free adhesives thus eliminates existing familiar drawbacks and presents an excellent alternative for many different applications. Whatever the requirement – high-speed machines or slow labeling processes, cold or hot, dry or wet conditions, heavy labels or thin aluminum foils, condensation-water resistance or extreme resistance to ice water – the Optal XP product series always includes a suitable adhesive. Key brewing customers are now employing these innovations for a huge range of labeling systems on returnable and disposable bottles. In addition, market testing was recently carried out for further Optal products that offer labeling solutions for PET returnable packages and even for containers with the up-and-coming no-label look. The printed, transparent labels stay firmly in place even after temperature changes and prolonged storage in ice water, for example. For every labeling option, there is an Optal XP adhesive to match. The diversified property and performance profile of the new generation of adhesives helps to produce ideal bottle designs to make the brand stand out effectively at the point of sale and achieve market success, without putting any constraints on existing processes.
Henkel AG & Co. KGaA
Sustainability as a market trendLabeling adhesives have been consistently optimized over the past few years with the goal of leaving established processes at beverage bottling plants unchanged while offering extra functional advantages. The trend toward sustainability has been making a lasting impression on the market here, as well. The growing environmental awareness of consumers and also of beverage bottlers has stimulated further demand for environmentally compatible production processes and products. Demonstrating entrepreneurial responsibility in its bid to efficiently satisfy consumer needs, the industry is investing heavily in application-driven research and development. It aspires to continuous improvement and innovative, sustainable solutions that open up new opportunities. Many companies have a traditional commitment to products based on renewable raw materials like casein and special starches. The beverage industry, for instance, often uses water-based casein adhesives to label glass containers.
The rising cost of renewable resourcesDespite their proven properties, such adhesives have their constraints. Renewable raw materials are subject to strong price fluctuations, and manufacturers are often confronted with rising costs due to increasing demand coupled with supply volatility. For example, seasonal effects and climate changes can impact on the available quantities of the derived renewable raw materials. Markets also tend to respond in a volatile and speculative manner to fluctuations in the supply situation. The price of casein, for example, has soared in the last few years – and experts anticipate that this trend will continue. Constantly rising prices for casein – a raw material derived from cow’s milk – have also driven up the cost of conventional labeling adhesives.
Always the right product for trouble-free production processesFor many years now, both beverage manufacturers, such as breweries and mineral water bottlers, and adhesives manufacturers have therefore been looking into alternative substances that are less susceptible to price fluctuations, whose performance features contribute to environmentally compatible processes and whose low complexity facilitates ease of processing. Casein-free adhesives are therefore being increasingly used, as they offer not only a longer shelf life and temperature stability, but also a whole series of further advantages over conventional labeling adhesives. These novel products based on robust polymers feature exceptionally good initial tack, for example, while supporting fast setting and drying, thus helping to reduce adhesive usage rates. They represent an effective alternative to products based on traditional resources and make it possible to save up to 30 percent on adhesives. For the industry, this expansion of the range of adhesives means greater production and budgeting security. This becomes all the more important when one considers that natural polymers may become scarce and the market situation can quickly change. With this extended range of options in adhesives, bottlers can thus make choices that cut their costs and ensure trouble-free production processes.
Tough requirementsHowever, anyone considering a switch to casein-free labeling adhesives should bear in mind a number of points when assessing the possible overall costs and the most suitable adhesive. These include the volume of waste and resource availability along with storage life and waste water treatment. The adhesive should be able to withstand wide-ranging conditions without showing any changes in its product characteristics. At the same time, it should be versatile in order to cover a broad range of labeling applications, have a neutral odor, ensure rapid drying and not disrupt the cleaning cycles of labeling machines. Furthermore, the adhesive should support the beverage bottler in his efforts to boost the efficiency of his plant by reducing the consumption of cleaning agents, additives, water and energy – and hence the production costs. These tough requirements are fully satisfied by Henkel’s improved generation of casein-free labeling adhesives.
Innovative and casein-free – performance without constraintsA number of demanding challenges have to be mastered, particularly in the returnable bottle sector. For example, it has to be possible to wash off the label during the defined cleaning process. Foaming in bottle cleaning machines has to be restricted, which today still often means high levels of defoaming agents during the wash-off process. The adhesives industry has been investigating effective solutions to these problems for some time now. As the leading supplier of adhesives technologies, Henkel embarked on the development of casein-free adhesives with equivalent bonding and processing characteristics back in the late 1990s. With its second generation of casein-free adhesives, the company now has a product series for glass bottle labeling that has a broader and more comprehensive performance spectrum and can be deservedly termed a pioneering, landmark innovation. Long-term tests have shown that the Optal XP product line meets these high customer expectations. In addition to their excellent wet tack, the adhesives exhibit good adhesion even to chilled glass surfaces. The food and beverage industry can therefore turn to a powerful and efficient range of products that cover the entire spectrum of bottle labeling needs, including sophisticated adhesive solutions with high ice-water and condensation-water resistance.
Economic and ecological process benefitsUnlike their conventional counterparts, these adhesives are based on synthetic polymers and are hence independent of the dairy industry. The raw materials employed are thus subject to lower price volatility than casein. For bottling plants, greater price stability means improved cost estimation security in their budgeting. The elimination of casein also yields further benefits, as this resource then becomes available for food production instead of being processed for technical purposes.
The use of Optal XP adhesives yields economic and ecological process benefits in terms of mileage and their field-proven wash-off behavior. Long-term use by various national and international beverage bottlers has shown that the labels can be detached with ease in bottle washing plants using standard cleaners and settings (see illustration 2). In addition, these second-generation adhesives give no cause for concern during waste water treatment. The products also have FDA approval, are free of toxic ingredients and contain no alkylphenol ethoxylates, zinc or borax.
With their outstanding machinability properties and greater efficiency in production due to improved processes and reduced complexity, the adhesives contribute to environmentally compatible production and thus offer bottling plants an equivalent alternative adhesive that is not formulated with resources from the food sector.
Ideal product design with added valueThe new generation of casein-free adhesives thus eliminates existing familiar drawbacks and presents an excellent alternative for many different applications. Whatever the requirement – high-speed machines or slow labeling processes, cold or hot, dry or wet conditions, heavy labels or thin aluminum foils, condensation-water resistance or extreme resistance to ice water – the Optal XP product series always includes a suitable adhesive. Key brewing customers are now employing these innovations for a huge range of labeling systems on returnable and disposable bottles. In addition, market testing was recently carried out for further Optal products that offer labeling solutions for PET returnable packages and even for containers with the up-and-coming no-label look. The printed, transparent labels stay firmly in place even after temperature changes and prolonged storage in ice water, for example. For every labeling option, there is an Optal XP adhesive to match. The diversified property and performance profile of the new generation of adhesives helps to produce ideal bottle designs to make the brand stand out effectively at the point of sale and achieve market success, without putting any constraints on existing processes.
Henkel AG & Co. KGaA
Tuesday, 13 November 2012
Seacourt
Notes on Seacourt lecture
5 dec 1995 they were visited by the Paint Research Association - wanted to do an environmental audit on their business. They did well but there is always room for improvement. They produced lots of waste. Emmisions were audited etc.
306 bins per anum waste created that went straight to landfill.
1997 - Decision to go waterless offset. Installation of first waterless offset printing machine.
1998 - registration to ISO 14001 environmental accreditation. (14001 means ----)
1999- 2nd printer worldwide to be EMAS environmentally accredited. (EMAS is to show ongoing improvement year on) Installation of large 5 colour waterless offset machine, has better results then litho printing.
2001- became carbon neutral. decision to go to recycled paper route, decision to use vegetable oil. mineral based inks create VOC's. Saved emmisions by 0.5%.
When they went waterless they saved 96%.
2003-switched to 100% renewable energy. cost 20,000 a year more to go to renewable power.
2004- started winning awards. 2008- Emas Uk award.
2009- platemaking water recycled (99.5% water reduction) saves 140,000 litres per year.
As a business their water usage is less then the average family home.
First printer in the world to become Zero Waste to landfill
2009-Digital printing machines installed. Citri toner (organic based, used far less power then conventional toner).
Had the Queens award for Sustainable Development twice.
2012 - large format production commenced. printing onto bamboo fibre, avoid pvc.
5 dec 1995 they were visited by the Paint Research Association - wanted to do an environmental audit on their business. They did well but there is always room for improvement. They produced lots of waste. Emmisions were audited etc.
306 bins per anum waste created that went straight to landfill.
1997 - Decision to go waterless offset. Installation of first waterless offset printing machine.
1998 - registration to ISO 14001 environmental accreditation. (14001 means ----)
1999- 2nd printer worldwide to be EMAS environmentally accredited. (EMAS is to show ongoing improvement year on) Installation of large 5 colour waterless offset machine, has better results then litho printing.
2001- became carbon neutral. decision to go to recycled paper route, decision to use vegetable oil. mineral based inks create VOC's. Saved emmisions by 0.5%.
When they went waterless they saved 96%.
2003-switched to 100% renewable energy. cost 20,000 a year more to go to renewable power.
2004- started winning awards. 2008- Emas Uk award.
2009- platemaking water recycled (99.5% water reduction) saves 140,000 litres per year.
As a business their water usage is less then the average family home.
First printer in the world to become Zero Waste to landfill
2009-Digital printing machines installed. Citri toner (organic based, used far less power then conventional toner).
Had the Queens award for Sustainable Development twice.
2012 - large format production commenced. printing onto bamboo fibre, avoid pvc.
Saturday, 10 November 2012
Wednesday, 7 November 2012
Packaging for Lea & Perrins
http://www.greenbottle.com/
Packaging waste is a huge and growing problem for modern society, with efficient 'green' disposal of plastic waste a particular issue.
Every day the UK throws away an estimated 15 million plastic bottles. While recycling rates are increasing they are still a long way away from 100%, and if plastic is not recycled it will soon find its way to landfill. Once there, because plastic does not biodegrade, it will persist for hundreds of years. Disposal of laminated cartons, the other predominant form of packaging for liquid consumer products, faces similar problems.
GreenBottle is a new type of liquid packaging designed as an environmentally friendly alternative to plastic bottles and laminated cartons. The bottle is made from a paper outer shell with a thin plastic liner inside to hold the liquid. After use, the bottle is easily separable, so that the paper outer can be composted or recycled, and the inner liner recycled where facilities exist. The bottle performs the same in distribution, in the store, and in the home as a regular plastic bottle, but with the advantage of being much better for the environment as it uses much less plastic.
Greenbottle has a much lower carbon footprint than a regular plastic bottle, and has a third of the plastic of a comparable plastic bottle.
The product benefits of GreenBottle in a nutshell are:
- Excellent shelf standout and strong visual and tactile appeal
- GreenBottle is recyclable and the outer shell is biodegradable/compostable
- The outer shell will be largely made of recycled material
- Carbon footprint is significantly less than an equivalent plastic bottle
- Uses less than one third of the plastic of a comparable plastic bottle
- Easy for consumers to understand/use, and preferred over plastic bottles
Research and in-market testing has consistently shown that consumers 'get' GreenBottle, find it easy to use and, given the choice, prefer GreenBottle over equivalent plastic bottles.
GreenBottle has consistently been preferred by consumers to conventional plastic bottles in research in the milk, detergent and juice categories. In a test market in Asda stores, sales of local milk increased significantly, selling at a rate of three bottles to one when sold in GreenBottle versus plastic.
In the milk category, research indicated a positive intention to try of over 90%
Our wine bottles weigh just 55g versus 400g for a glass 750ml bottle and therefore will yield a considerable fuel and carbon footprint saving in distribution, and are lighter for the customer to carry home.
Wine chilled in GreenBottles will stay cooler for longer on the table. Recycling is easier for the consumer and more effective; glass bottles are mostly ground for road aggregate (Recycle-direct.com). Glass production is very energy intensive, and haulage costs are likely to be considerably lower when using GreenBottle in place of glass.
Much of the UK wine market is bottled in the UK; of the 1.2 billion litres sold in the UK, 30% are bottled in the UK.
GreenBottles are designed so that after use they can easily be opened, the paper and plastic elements separated, and each disposed of appropriately:
 | GreenBottle is ripped in two by pressing finger under the flap at the top, and pushing all the way down under the flap to open out the bottle. |
 | The plastic inner can then easily be separated all in one from the paper outer. |
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The two separate parts of the bottle can then be disposed of; the paper outer onto a compost heap or into paper recycling, and the plastic inner into plastic recycling where facilities are available.
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