Unpacking the Plastic Packaging Waste Problem

Packaging is the largest end-use market segment accounting for just over 40% of total plastic usage. Plastic packaging might seem less sustainable and better than other packaging materials, but this is not always true. Many factors go into choosing sustainable packaging materials, such as the intended use, transportation process, and disposal method.

The Rise of Plastic

In 1907, Belgian chemist Leo Baekeland invented the first fully synthetic plastic made by combining formaldehyde and phenol under heat and pressure. This lightweight, opaque plastic was used for telephone casings, saucepan handles, electrical sockets, and ashtrays.

Throughout the years, other types of plastics were developed and mass-produced, such as cellophane in 1908, PVC in 1926, polystyrene in 1931, and polyamide in 1935. Plastics that we use each day were introduced in the second half of the 19^th century, such as polyester in 1949 and high-density polyethylene in 1953.

Through improvements, plastics became easier and cheaper to mass produce, introducing the single-use plastic boom. Although single-use plastic has only been around for around 70 years, more than 9 billion tons have been created.

Why is So Much Plastic Used in Packaging?

Today, the average American uses about .75 pounds of plastic each day, resulting in over 250 pounds a year. Plastic is a prevalent material in packaging due to its versatility, durability, and cost-effectiveness. However, the environmental impact of plastic waste has become a significant concern for consumers worldwide.

Benefits:

• Strong Barrier - Plastic provides excellent barrier properties against moisture, oxygen, and contaminants, extending the shelf life of products.
• Design Flexibility - It can be molded into various shapes and sizes, making it suitable for a wide range of products.
• Lightweight - Plastic is lighter than many alternatives, reducing shipping costs and carbon emissions. This also means more products can be shipped at once, reducing transportation costs.
• Lower Production Costs - Plastic is relatively inexpensive to produce and process, making it a cost-effective option for manufacturers.
• Protective Properties - Plastic packaging is durable and can protect products from damage during transit and handling. It's also resistant to breakage, ensuring the safety of the product until it reaches its final destination.

What Causes Plastic Packaging Waste?

The biggest causes of plastic waste are over-packaging, lack of proper recycling infrastructure, and single-use convenience.

• Extra Product Protection - Ensuring product safety during transit sometimes leads to using more packaging than necessary.
• Added Visual Appeal - To attract consumers, companies sometimes use excessive nonfunctional packaging for aesthetic appeal.
• Recycling Issues- Recycling facilities' capabilities vary across the globe. Not all regions have adequate recycling, leading to a significant amount of plastic waste ending up in landfills. Also, contaminated or mixed plastics can be challenging to recycle efficiently.
• More Convenient - The convenience of single-use plastic products contributes to their widespread use and waste disposal.

In some cases, there might not be a fully suitable alternative to plastic due to specific product requirements. For instance:

Food Packaging - When packaging food, plastic often increases the freshness of produce and meat, extending shelf life by 5 to 10 days longer, and reducing the amount of food being thrown away by about 16%. Additionally, using plastic instead of glass to package food items, such as yogurt, drastically decreases weight during transport. A yogurt container made from glass weighs about 85 grams and accounts for about 36% of the weight during transportation. Alternatively, yogurt containers made from plastic weigh only 5.5 grams, resulting in a significant reduction in transportation emissions.

More biodegradable packaging solutions are being created to combat the plastic waste problem. PeelOn, a leading provider of biodegradable packaging solutions, is dedicated to creating sustainable and innovative packaging solutions that keep produce fresher for longer.

Healthcare & Medical Packaging

The healthcare industry uses plastic packaging for blister packs, IV bags and tubing, device packaging, prescription bottles, and more. Depending on the application, plastics used in medical packaging undergo a series of rigorous tests to ensure safety and stability for the intended use. Unlike other packaging, plastics are more sterile and stable in the healthcare industry. For example, studies show that blood stored in glass containers has a much higher rate of hemolysis (the rupture or destruction of blood cells) than blood stored in plastic containers.

Alternative Materials & Packaging Optimization

Understanding the reasons behind the widespread use of plastic in packaging and its waste can help us take steps toward more sustainable practices. By exploring alternative materials and improving recycling infrastructures, companies can reduce their environmental impact while still meeting their packaging needs. Employees responsible for researching new packaging materials play a crucial role in driving these changes and fostering a more sustainable future.

Alternative Materials to Consider

Biodegradable Plastics (Plant-based polymers and compostable options)

Paper and Cardboard (Many styles and types of packaging that are recyclable and biodegradable)

Glass or Metal (Reusable packaging)

Agricultural or Plant Fibers (Mushroom, seaweed, algae-based, plant-fiber materials)

Material and Design Optimization

By optimizing the packaging materials currently in use, plastic waste can be significantly decreased. Most manufacturers and suppliers use stretch wrap to secure boxes or products on a pallet to add extra protection during storage and transportation. Ensuring that your stretch wrap is the optimal gauge and consistently wrapped can save an average of 50% in cost and waste.

Customer Sustainability Success Story - See how we helped a paper manufacturer reduce its yearly plastic usage by 7 tons!

Our team of packaging specialists and engineers can run a packaging audit to ensure your machinery is running optimally and the best materials are being used to reduce waste and cost. Contact our team today to set up a packaging optimization audit.