This document discusses sustainable paper packaging. It begins by outlining the categories of packaging and the purposes of packaging. The key elements of packaging including materials and design are then examined. Various materials used for packaging like metals, glass, polymers, wood, and paper are described. The concept of sustainability and sustainable development are defined, with sustainable packaging focusing on being beneficial throughout its lifecycle. Issues with paper packaging consumption rising and quality of raw materials are discussed. Using oil palm biomass fibers as an alternative raw material source is presented as a solution to improve raw material sustainability for Malaysian paper packaging. Clean pulping and bleaching technologies are also described to enhance environmental sustainability of pulp production.
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Sustainable Paper Packaging
1. SUSTAINABLE PAPER
PACKAGING
(PEMBUNGKUSAN KERTAS
LESTARI)
INTERNATIONAL SYMPOSIUM ON
CURRENT ADVANCEMENT AND
RESEARCH IN TEXTILE & PACKAGING
TECHNOLOGY
Wan Rosli Wan Daud
Universiti Sains Malaysia
2. Packaging falls into a number of
categories:
§ Primary –packaging in contact with the
product.
§ Secondary –‘outers’ which hold a number of
packed products as a unit of say 10 or 12.
§ Tertiary –stretch wrapped pallets which hold
perhaps 100 ‘outers’ or cases.
4. PACKAGING
put in another way:
§ is a means of ensuring safe delivery of a
product to the ultimate user in a sound
condition at a minimum overall cost
§ Science
§ Art
§ Technology
5. ELEMENTS OF PACKAGING:
§ Materials
§ Design
- address the issue of wastage
- under-packaging cause damage and
spoilage to contents
- over-packaging wasting resources
- goal is “RIGHT SIZE” packaging
- packaging design software eg PIQET,
Australia (Packaging Impact Quick Evaluation
Tool); TOPS, USA (Total Optimization
);
Packaging Software)
8. § Measures taken by various sectors to
allay fears of sustainability centers
around the traditional waste management
hierarchy – 3R’s
§ Reduction
§ Reuse
§ Recycling/Recovery
10. Sustainable Development
Entered the public debate after the World
Commission on Env. And Dev. Published
their landmark report “OUR COMMON
FUTURE “ in 1987
Reiterates the most often quoted
definition (Brundtland Commission
(United nations, 1983):
“meets the needs of the present
without compromising the ability of
future generations to meet their own
needs”
needs”
11. Sustainable packaging
§ Is beneficial, safe & healthy for individuals and
communities throughout its life cycle;
§ Meets market criteria for performance and cost;
§ Is sourced, manufactured, transported, and recycled
using renewable energy;
§ Optimizes the use of renewable or recycled source
materials;
§ Is manufactured using clean production technologies
and best practices;
§ Is made from materials healthy in all probable end-of-
life scenarios;
§ Is physically designed to optimize materials and
energy;
§ Is effectively recovered and utilized in biological
and/or industrial closed loop cycles.
www.sustainablepackaging.org
12. Sustainable Development
Most often quoted definition (Brundtland
Commission (United nations, 1983):
“meets the needs of the present without
compromising the ability of future generations to
meet their own needs”
needs”
Can be conceptually broken into three
constituent parts:
§ environment,
§ economic and
§ social
14. § With paper packaging there has never
been an issue regarding sustainability
– its always sustainable
§ WHY?
16. Environmental Dependable
§ Made from renewable resources
§ One of the highest recovery rate of all
packaging
- almost 60% of paper are recycled
§ Almost total compostable
17. Socially Dependable
§ Produced by manufacturers who
practised high safety standards
– ISO 9000 series
§ Charitable donations from companies to
community
§ Industry involve educating the public the
importance of recycling through school
and outreach programs
20. CONSUMPTION OF CORRUGATING
MEDIUM IN MALAYSIA
X000 TONNES
600
400
200
0
1992 1996 2000 2004 2008
YEAR
Asian paper Packaging Historical Data, 2009
21. §Problems in sourcing of and
quality of raw material
§Issue of Raw Material
Sustainability
22. Social Environmental
sustainability sustainability
SUSTAINABLE
PAPER PACKAGING
Raw material Economic
sustainability sustainability
FACTORS IMPACTING SUSTAINABLE PAPER
PACKAGING, AND THEIR INTERDEPENDENCE
24. Raw material for paper and paper
packaging are the cellulose fibers
§ hygroscopic property (absorb moisture)
25. Malaysia being in the equatorial region
has high humidity
§ effect on paper strength properties
26. How to overcome this problem?
Yield Pt. NSSC
KLB
UKP
Load
1
Stretch
High Humidity Resistance of
Various Pulps
27. Another critical issue
relating to raw material
sustainability is Quality of
raw material
§ Basically most of all paper packaging in
Malaysia uses recycled fibers
§ Problem of strength
34. § Loss of swelling ability of
cellulosic fiber upon drying
§ due to the closure of pore
spaces in the cell walls, plus
§ the inability of many of the
pores to reopen if the fibers are
rewetted
35. WETTING
A B
DRYING
Progressive swelling of fibre wall: from A to D
Progressive shrinkage of fibre wall: from D to A
C
D
35
36. DRIED FIBRES
NEVER-DRIED FIBRES
CHEMICAL PULP FIBRES
36
37. Factors that influence
Hornification
§ High-yield pulps, such as
thermomechanical pulp (TMP),
appear to be much less
susceptible to changes when they
are dried
41. MALAYSIA - SOURCES OF IMPORTED
VIRGIN PULP
Others,
11% Chile,
4%
Canada,
5%
Thailand, 7%
USA, 59%
New Zealand,
14%
Importation of wood pulp to Malaysia is
dominated by USA
Total imports of wood pulp in 2002 is ca.
RM138 Million with a growth of 5.6%
compared to 2001
42. “Let the building and
other critically wood-
wood-
dependent industries use
wood. Pulp and paper
industry should opt to
non-
non-wood and wastes for
sustainability”
sustainability”
Ako Norlander, Appita J. 2008
43. Pulp from oil palm
biomass as
reinforcement in
recycled fibers
44. Palm oil constitutes only 10% of the palm
production while the rest is biomass
The biomass (waste residues) generated
from this industry throughout harvesting and
processing activities as well as during
replanting is enormous
§ Estimated to be 60-100 million tonnes (wet)
60-
Forms of waste residues:
§ Empty fruit bunches (EFB)
§ Fronds
§ Trunks
45. BIOMASS/PRODUCTS FROM
OIL PALM TREE
Fronds
Empty Fruit
Bunch
Fresh Fruit Bunch
Crude Palm
Oil
Oil Palm Tree
Trunk
46. § An estimation, based on a planted area of
25,700 million m2, and a production rate of dry
oil palm biomass of 20,336 kg per 10,000 m2
per year, shows that Malaysian palm oil
industry produced approximately 56.9 million
tonnes of lignocellulosic biomass in 2000.
§ Taking into account the proportion of useful
fibrous elements that can be extracted from
various oil palm components, an overall
recovery rate of 75% and a pulp yield of 45%,
the net useful bleached pulp would amount to
about 14.8 million tonnes
§ VERY SUSTAINABLE
51. For a sustainable pulp production
§ other than a continuous supply and availability
of raw materials,
§ the processes involved in the production of
pulp and paper have to be environmentally
friendly
§ Nevertheless, process(es) must be economic
viable, if not it will just be an academic study,
without having much impact on the society in
the long term
52. Kraft, Sulfite
Pulping
Raw material Unbleached Pulp
Cl2 & derivatives
Bleached Pulp
PRODUCTION OF PULP
53. These processes (esp. bleaching) are
known to generate serious environmental
drawbacks
§ Chlorine reacts with lignin, to form chlorinated
organic compounds (e.g., dioxin)
dioxin)
o believed to be carcinogenic to humans based on
results of laboratory studies with animals
§ The presence of these chlorinated compounds
has also been linked to adverse ecological
effects on wildlife in receiving waters
54. § And to reduce these shortcomings,
it is imperative that alternative
methods which are cleaner and
environmentally friendly are used
§ ENVIRONMENTALLY
SUSTAINABLE
55. ENVIRONMENTAL
SUSTAINABILITY
§ Environmental sustainability is
defined as the ability of the
environment to continue to function
properly indefinitely
§ Goal to minimize environmental
degradation, and to halt and reverse
the processes they lead to
§ Clean Technologies for Pulp
Production
57. “manufacturing processes or product
technologies that reduce pollution or
waste, energy use, or material use in
comparison to the technologies that
they replace”
process(es) must be economic viable, if
not it will just be an academic study,
without having much impact on the society
in the long term
environmentally friendly –
SULFUR FREE PULPING AND CHLORINE
FREE BLEACHING
58. CLEAN TECHNOLOGY FOR
PULP PRODUCTION
Oil Palm Pretreatment
1. Soaking
Empty Fruit 2. Washing
Oily substance removal
Bunch 3. Mechanical process – silica
removal
(In strand form)
Unbleached Pulping
EcoPalm Pulp™ Extended Soda
Anthraquinone
TCF Bleaching
1. Oxygen Bleached
2. Ozone EcoPalm Pulp™
3. Hydrogen Peroxide
59. COMPARISON OF PAPER PROPERTIES
FROM OIL PALM EFB AND
COMMERCIAL HARDWOOD PULPS
(UNBLEACHED)
Tensile Tear Index Burst
Index (mN.m2g-1) Index
(Nm/g) (kPa.m2g-1)
Commercial 13.21 3.14 1.0
Hardwood
Empty Fruit 15.81 3.85 1.20
Bunch
60. COMPARISON OF PAPER PROPERTIES
FROM OIL PALM EFB AND
COMMERCIAL HARDWOOD PULPS
(BLEACHED)
25
20
15
10
5
0
Tensile Index Tear Index Burst Index Brightness
(Nm/g) (mN.m2g-1) (kPa.m2g-1) (x 10%)
Commercial Hardwood Pulp 19.55 2.6 1.4 8.43
Empty Fruit Bunch Pulp 20.41 2.72 2.46 8.33
61. POTENTIAL PRODUCT APPLICATION(S)
Unbleached virgin pulp (Unbleached
EcoPalm Pulp™) which can be used in
Pulp™)
full or mixed with wastepaper depending
on the final product
Bleached virgin pulp (Bleached
EcoPalm Pulp™) which can be used in
Pulp™)
the production of writing and printing
paper
62. Yield Pt. NSSC
KLB
UKP
Load
1
Stretch
High Humidity Resistance of
Various Pulps
64. Alkaline Peroxide
Mechanical Pulping
(APMP)
process involves the impregnation
of the chips with an alkaline
peroxide bleach liquor in one or
more steps prior to atmospheric
refining, hence combining pulping
and bleaching in a single operation
65. Attractive Features of
APMP
§ High yield (85% on average), compared
to 50% or lower yield of chemical pulping
§ High brightness – use of peroxide
§ Can also be use for newsprint
67. Packaging Source
Reduction
§ Avoid unnecessary components
§ Eg: Toothpaste boxes have been
eliminated in countries with strict waste
laws
§ Reduce amount of material
§ Eg. Nike
69. “Lightweighting”
§ Lightweight packages produce less
waste than packages manufactured from
heavyweight materials
§ Requires new designing and technolgies
since lightweight material generally are not
stronger
§ Softdrink manufacturers have manage to
reduce PET up to 5%
78. § bottles made with nanocomposites that minimize
the leakage of carbon dioxide out of the bottle; this
increases the shelf life of carbonated beverages
without having to use heavier glass bottles or more
expensive cans
§ food storage bins with silver nanoparticles
embedded in the plastic. The silver nanoparticles
kill bacteria from any food previously stored in the
bins, minimizing harmful bacteria.
§ CONCERNS: Because the particles are
so small, these materials might be able
to migrate into food
79. § Nanopartcles (eg. nanoCeO2 and TiO2)
have been used to increase UV
resistance in plastic packaging
§ Other nanomaterials have the
potential to improve a variety of
packaging-
packaging-performance attributes
such as oxygen and moisture
blockage, ink or dye-free coloration
dye-
and increased strength while
lightweighting.
81. INNOVATIVE NEW FIBERS
FOR PACKAGING
through Surface
Functionalization/derivatization
§ Moisture stable
§ Breathable
§ Enhanced strength properties to allow for
lightweighting
§ Paper foam packaging
§ Controlled diffusion packaging
82. Real problem with
sustainable paper
packaging in Malaysia is
Raw Material
Solution: Use Oil Palm
Biomass Fibers as raw
material
85. "Don't keep forever on the public
road, going only where others
have gone.
Leave the beaten track occasionally
and dive into the woods.
You will be certain to find something
you have never seen before.“
86. DESCRIPTION OF
THE
ENVIRONMENTALL
FRIENDLY
TECHNOLOGY
PROCESSES
89. EFBs are obtained following the extraction
of the palm oil, nevertheless, part of the oil still
remains, which, if not removed will cause
considerable reduction in pulp quality and its
subsequent products.
Hence, the first step is minimizing the oil
content in the raw material
90. Fig. 1: The brown Fig. 2: The after washed
coloured washed and unwashed EFB fibre
water, suspected of strands.
containing some oily
substance, water-
soluble lignin, and
extractive
91. As with most non-woody material,
EFB also contains a substantial amount
of 1% silica, which can increase liquor
viscosity thus posing problems in
chemical recovery. In addition, its
presence could cause abrasion of
metals during papermaking and also
reduce paper quality.
93. As part of the technology, a simple
mechanical process has been
developed that could remove almost
80% of the silica present. It is
postulated that during this mechanical
treatment, the silica is dislodged from
the fiber surfaces as evident from the
scanning electron microscope pictures
(Fig. 3) and later washed out during
the washing stages
94. Plate 1: Initial surface of EFB (P) Plate 2: Cracks attributable to
with silica lodged mechanical treatment as evident on Q
Fig. 3: The Effect of
Mechanical Treatment on
EFB fiber
Plate 3: Removal of metals by
washing assisted dislodge of silica.
96. Pulping chemicals used:
used:
sodium hydroxide and anthraquinone but
with extensive modifications of the
pulping parameters (henceforth called
Extended Soda Anthraquinone Pulping)
Either the cooking time for pulping or the
pulping temperature is increased to
provide extended delignification.
delignification.
98. The brown color of unbleached pulp is
mainly associated with its lignin component.
component.
To reach an acceptable brightness level, this
residual lignin has to be removed through a
series of bleaching sequences.
sequences.
Common bleaching chemicals today are
chlorine and chlorine dioxide, which has
been blamed for the environmental issues
created.
created.
99. Sequences and optimization of parameters
are of paramount importance for a
successful bleaching process; failure in
process;
either of these two aspects will contribute to
an inferior quality cellulose pulp resulting in
a low -grade end product.
low- product.
In tandem with global requirements, the
bleaching treatment put forward in this work
is of the following sequence: Oxygen (O),
sequence:
Ozone (Z) and Peroxide (P), with inclusion of
several chemicals to increase the reactivity
of each step. In addition the pulp was
step.
washed in between the processes.
processes.
111. § cellulose acetate an acetylated cellulose used as
a hemodialyzer membrane.
§ oxidized cellulose an absorbable oxidation
product of cellulose, used as a local haemostatic
cellulose,
(also in wound dressing)
§ Carboxymethylcellulose a substituted cellulose
polymer of variable size, used as the sodium or
calcium salt as a pharmaceutical suspending agent,
tablet excipient, and viscosity-increasing agent; the
viscosity-
former is also used as a laxative.
laxative.
§ cellulose sodium phosphate an insoluble,
nonabsorbable cation exchange resin prepared from
cellulose; it binds calcium and is used to prevent
formation of calcium-containing renal calculi.
calcium-
112. § cellulose phosphate an insoluble material which
has the potential to be used in orthopedic
applications
§ Microcrystalline (MMC), is widely used in the
pharmaceutical and food industries for several
applications and enjoys the generally recognized as safe
(GRAS) status
§ Cellulose viscose sponges have also been proposed
as implantable tissue matrices for connective tissue
regeneration.
§ Cellulose regenerated by the viscose process has
also been investigated as an implantable material in
orthopedic surgery, as a sealing material for the femoral
component in hip prostheses, in place of acrylic cement.
114. § Pulp mills based on the oil palm biomass
are attractive to our palm oil industry
because of several benefits.
v Firstly, it will help to decrease rural
depopulation
v Secondly, there will be a reduction in the outflow
of the currency due to fewer imports of paper
and paper products.
v Thirdly, it will help create new pulp and paper
technologies and also new products which are
currently being developed in our laboratories.
v And, finally, it will create economic growth for
the nation.
115. § However, the use of conventional technology in
processing oil palm biomass is of little interest due
to the overwhelming environmental problems
generated.
v Thus to promote sustainable development, the
pulp mill based on oil palm biomass should be
able to operate free from sulphur and chlorine
and its derivatives and the cellulose pulp
produced should be of comparable quality to its
woody counterparts.
§ The proposed environmentally friendly technology
consisting of the three or five sequences meets
these demands and probably even more.
§ Sustainable pulp production from oil palm biomass
using the proposed environmentally friendly
technology is definitely close to reality.
116. Being both a tree-free and
tree-
hazardous-
hazardous-free paper, this
product (EcoPalm Paper™)
(EcoPalm Paper™)
fulfills itself as one of the truly
environmentally friendly paper
of our time.