Appropriate Food Packaging (Tool) 5 Production, re-use and re-cycling of packaging (introduction...) 5.1 Materials that can be made on site 5.2 Re-use of packaging 5.3 Environmental aspects of packaging and re-cycling possibilities

Appropriate Food Packaging (Tool)

5 Production, re-use and re-cycling of packaging

Most small and medium-scale food manufacturers will purchase their packaging ready-made from a supplier. Such packaging will either be standard lines such as bottles, paper and films or special lines such as wooden boxes or pottery. This chapter describes the opportunities that exist for food processors to make their own packaging on site in cases where external sources may be difficult to find or too expensive. It ends with a brief discussion of environmental aspects of packaging and opportunities for re-use and re-cycling of packaging.

The manufacture of packaging that is bought readymade has been briefly described in the relevant sections of this publication. It must be remembered that ordering 'special' packaging from large suppliers will always be very expensive. However in many countries there are medium-sized companies that can make up packaging to order which may prove cheaper and more economic (because they are prepared to accept smaller orders) than importing standard packaging from the large suppliers. When looking for packaging supplies it is worth exploring local sources. Such medium-sized suppliers will mainly make:

- cardboard boxes, often printed,
- paper bags, often primed,
- plastic bags, often printed,
- pottery and ceramic containers,
- wooden crates, boxes, etc.

In some cases it is possible to produce packaging which is normally made at very large scale with scaled-down equipment. Examples include:

- the production of moulded paper pulp trays and egg boxes from waste paper, which has been described in Chapter 3.1.6,
- the small-scale vacuum forming of shallow tubs, etc., from sheet plastic, as illustrated in Figure 3.23,
- the manufacture of tins for packaging of oils or powders at rates between 20 and 1000/hr depending on the equipment used, briefly mentioned in section 3.1.3, a small entrepreneur in Sri Lanka who developed a production system for approximately 5000 push-on type jam jar lids per day.

The application of such appropriate scale manufacturing could be of considerable benefit in some developing countries. Benefits would include increased availability of packaging for local industry, saving of foreign exchange by import substitution and job creation. Unfortunately information and access to these appropriate scale packaging material production systems is difficult. They are mainly produced by small companies who do not advertise their equipment widely. It would seem that there is a role for International Development Agencies, interested in assisting the small-scale food processing sector, to draw together information and experiences and disseminate such technologies.

5.1 Materials that can be made on site

Some packaging can be made on site by the food manufacturer. The most common examples are cardboard boxes and bags. Large sheets of cardboard are often available as waste from large companies and importers. It is perfectly feasible to cut out such board and make up boxes of the types described in Chapter 3.6, and even outer cases with dividers of the type used for bottles.

The method is simple and involves preparing an accurately cut out shape from a pattern which, when folded will make up into a box of the required size. It is best if the pattern is made from thin sheet metal. The pattern is laid on the cardboard and cut round with a very sharp blade. Next is generally best to lightly score the fold lines. The box is then folded and joints glued, taped or stapled using either retractable anvil staplers or stapling pliers depending on the type of join. Two designs for a two-piece and a one-piece box are shown in Figure 5-1. Making up the pattern does requires a lot of thought. One easy way to design the pattern is to carefully take apart a box of the style required and use this as the starting point.

Figure

Hand-made boxes with attractive glued labels can be a good option for small producers who cannot afford to buy large quantities of ready-made boxes.

Various fabrics or textiles can tee cut and sewn into small retail size bags that can be very attractive. Examples include small hessian sacks which are stencil printed for teas, coffees and spices and more colorful fabrics for sweets generally using an inner polythene bag. Such packaging gives 'style' and 'quality' to the brand image and may allow producers to penetrate new, higher-value markets.

Some manufacturers cut out small circles of attractive fabric and use them, tied with a ribbon, to cover the lids of jars of jam to make the product more appealing.

While paper and plastic packaging is not generally re-usable there are occasions in which bags can be made up in house from paper and plastic. In some situations it is possible to obtain used office stationery which can be cut down and glued to make simple bags. If this is planned it should be remembered that printing inks can be toxic and thus not allowed to contact the food directly. Unfortunately where such bags are made there is often a tendency to put the printed side of the paper inside the bag to give a better external appearance; the opposits would be better.

Plastic film off cuts are available from larger companies in some countries. These can be cut up and heat sealed into bags or tubes for packaging foods.

In all cases it will be found more efficient to cut round a pre-made metal template. The work will be quicker and the final bag more uniform in size. When using a template and very sharp blade it is also possible to cut several layers of paper or plastic at a time.

5.2 Re-use of packaging

5.2.1 Glass

Glass bottles are commonly re-used either by buying in second hand or selling the product in returnable bottles. In both cases the treatment of re-cycled glass is crucial for they must be inspected and properly cleaned.

The most serious risk when using second hand bottles is that they may have contained a poisonous substance such as insecticide. It is strongly recommended that a responsible worker in the plant checks each bottle visually and by smell and rejects any that are suspect. The payment of a bonus for the number of contaminated bottles, often acts as an incentive.

After examination the bottles need to be washed thoroughly. While commercial bottle washing powders are available most small producers will find it more convenient to use a 1 to 2% solution of caustic soda to which a standard 'washing-up liquid' is added. Remember that caustic soda will damage the hands. Operatives should wear protective rubber gloves. After washing the bottles must be thoroughly rinsed to remove all traces of detergents and caustic. This can be a time-consuming job, repeatedly rinsing till all traces of bubbles have gone, and the semi-automatic rinser shown below can speed up the process (Figure 5-3). If the bottles are not to be re-filled immediately after washing, but put into store, remember that they will need another rinse before filling.

Figure

If labelled returnable bottles are involved then it is worth using labels that will fall off easily in water (wet strength paper and water soluble adhesive) as described in the chapter on labelling. The actual washing operation should be carried out with bottle brushes which can usually be found in a local pharmacy.

When selling in returnable bottles the deposit charged is seldom enough to buy a new bottle. For this reason the average bottle must make a given number of trips to maintain economic production. The profitability of many small businesses depends on this average trip life of bottles so accurate records should be kept and pressure put on customers with a low return rate.

5.2.2 Drums and tins

Drums and tins are commonly re-used (Table 5-1) as they are very expensive to replace. The same warnings apply, as in glass above, regarding to their having been used for poisonous substances. They must be properly inspected and cleaned. Drums that are used for poisonous substances generally have warning markings on the outside, often a skull, and should never be used for packaging foods.

If drums or tins are to be used for packing oils they must be absolutely dry before filling since the presence of water will speed up the development of rancidity. It should also be remembered that oils packed in plain, unlined, steel drums will quickly go rancid.

Type	Main uses
Large drums	Oils, Intermediate storage of
	fruit juices, Vegetables in
	brine, Pickles and chutneys,
	Packed finished dry foods
Tins with pourer 1-5 gall	Oils
Push on lid tins	Dried foods

Table 5-1: Most common metal containers re-used

5.2.3 Plastic barrels and drums

Large plastic containers are increasingly replacing metal drums and can often be bought second hand. Once again the food producer must be certain that they have not been used for any toxic substance. In addition the food producer should check that the type of plastic is food grade. It is recommended that plastic drums are not used for packing oils or oily foods.

5.3 Environmental aspects of packaging and re-cycling possibilities

In many developed countries there is increasing concern over the environmental impact of packaging disposal. Indeed in some countries, most notably Germany, the small number of remaining waste disposal or land fill sites is causing grave concern. This is leading the government to consider moves in legislation that would make the packaging supplier or user responsible for the disposal of the waste they generate.

The effects of pollution can be seen in many parts of the developing world, especially in the cities. In some cities waste disposal is very inefficient, and in extreme cases almost non existent. Street litter and polluted air and water are causing health problems such as respiratory diseases. Re-cycling helps combat pollution by using materials that would be thrown away to make other materials. It may be cheaper to re-cycle than use new materials. Re-cycling may also replace imports and save foreign exchange. The recycling of glass and aluminium has considerable potential for saving energy.

All around the world waste, much of it hazardous, is being generated. Cairo, in Egypt for example produces 6000 tonnes of waste per day. The costs of dealing with waste are huge. Dakar, Senegal spends 52% of its city budget on waste disposal while Bangkok, Thailand spends US$ 40 million a year.

In many developing countries there is less concern and control over waste and packaging disposal than in northern countries. Food manufacturers however have the opportunity to show that they have a responsible attitude to the environmental impact of packaging. Fortunately in most developing countries foods are not, for cost reasons, overpackaged as they are in developed countries. Also the use of returnable containers such as bottles and metal drums is far more common and often forms a sub-industrial activity for very poor people. In developed countries, to a great extent due to consumer pressure, there has been a considerable growth in re-cycling as a profitable business. Sophisticated plants have been built which separate out valuable materials such as metal and glass. Many towns now have centres where people can dispose of wastes into different bins for cans, bottles, textiles, paper and aluminium.

Essentially there are two types of packaging materials those that break down under natural conditions (biodegradable) and those that nature cannot break down (non-biodegradable). Packaging can also be re-cyclable or non-re-cyclable. Table 5-2 shows common materials according to their possibilities for biodegradation, re-use and re-cycling.

Material	Biodegradable	Re-cyclable	Re-usable
Wood	highly	highly	highly
Paper	highly	highly	highly
Glass	not, but finally	highly	highly
	breaks down
Metal drums	not, but finally	slightly	highly
	corrodes
Tin cans	not, but finally	slightly	slightly
	corrodes
Cloth /	highly	moderately	highly
vegetable fibre
Thermoplastics	not	moderately	not
(films and
bottles)
Thermosetting	not	not	not
plastic
Cellulose films	highly	not	not
Ceramics	not, but finally	highly	highly
	breaks down
Aluminium	not	highly	not
cans, foil

Table 5-2: Biodegradability and recyclability of packaging materials

The responsible producer should thus:

- first give preference to a packaging material which is biodegradable,
- if this material is not suitable choose one that is recyclable or will eventually break down,
- only use plastics if essential and try and avoid those that cannot be recycled.

It should also be remembered that a growing number of consumers are becoming environmentally aware and 'green'. It may even help sales to state on the package that it is biodegradable or returnable.

Much research is being done to develop plastics that are either biodegradable or break down into tiny pieces under the action of sunlight for example. To date the materials developed are not widely commercially available. One biodegradable plastic, trade name Biopol, is recently reported to have found application to packaging of non-food items such as shampoos. With time it is hoped that biodegradable plastics will become affordable and the terrible environmental impact of discarded packaging a thing of the past.