Plastic is a material that fulfills all these requirements, is of mass use while being environmentally friendly. In fact, a report by the Ministry of Petroleum and Natural Gas estimated that the annual per capita consumption of plastic in India would be 20 kgs by 2022. In India, around 43% of manufactured plastics are used for packaging purposes. Therefore, taking a fresh look at packaging design in terms of complexity and weight can drastically impact the end-of-life of plastic-based packaging products. 

We work with FMCG and other consumer goods companies to redesign their packaging so they can optimise, differentiate, and grow their business in a more demanding world. In the past, our redesign projects have resulted in reducing up to 20% of plastic per package. 

We elaborate here our Restorative Design Engineering process to develop sustainable and eco-friendly packaging. 

Opportunity Mapping 

We start the process with a design and material research for segment-focused opportunities to help identify the end user’s usage application, geographic impact, and competitive edge a brand can have by adapting a new design. 

Idea Workshop 

This is stage is mostly a combined working session with our clients to identify new and differentiated packaging opportunities. At this stage, we usually present different design concepts and approaches that can be adopted to give the brand a new shape. 

Cost Modelling 

The ideation is followed by a Total Applied Cost analysis to clearly define and demonstrate the cost of switching from alternate packaging material to sustainable plastic and redesign benefits. 

Concept Development 

Using our advanced 3D printers, we develop prototypes, leveraging our broad portfolio of materials and technologies to create differentiated products without impacting valuable production time or resources. 

Market Proofing 

Once the prototype is developed, we work with our clients to do a line and shelf-life study to improve the operational excellence for our clients and help them raise their margins and competitiveness 

Converting & Application Support 

With eight manufacturing plants spread across India, we offer optimised converting with quick time-to-market and fast troubleshooting. For our customers, we provide on request support from our team of industry experts. 

Quality Assurance 

We offer exceptional physical & analytical testing from a dedicated, highly experienced team of QA experts, chemists, and material engineers using advanced testing laboratories and instruments. 

We have a team of sustainability specialists with knowledge of complex compliance requirements, emerging trends, and best practices. We also offer end-of-life management support to our customers by providing a viable solution in the form of premium recycled resins to fulfill their extended producer responsibility and neutralise the environmental impact of their packaging. 

Contact us here - https://www.manjushreeindia.com/contact-us to get your packaging designed or redesigned from us. 

1.       Using plastics in packaging applications requires less energy from both renewable and non-renewable energy sources than substitute materials. The energy saved is equivalent to the energy needed to fuel 18 million passenger vehicles. 

2.       In terms of weight, the life cycle of durable, lightweight plastic packaging, including post-consumer disposal, results in less solid waste. 

3.       Production of plastic packaging consumes significantly less water than alternatives, including in the waste stream. 

4.       The production and use of plastic packaging does not emit as much Green House Gas as other materials. The emission saved is equivalent to the emission from 8.5 million passenger vehicles. 

The unique nature of plastics, with its light weight, durability, flexibility, cushioning, and barrier properties allows plastic packaging to serve its purpose more efficiently while helping to reduce a variety of environmental impacts. Despite these important benefits, recognizing the plastic waste problem in the environment is necessary. 

At Manjushree we are working to build a more circular economy by using our plastics resources more efficiently, capturing and repurposing more post-use packaging, advancing recycling and recovery, and developing new transformative business models. We understand that the real challenge is in the end-of-life management of this wonder material. 

The first step we have taken towards solving the plastic waste problem is addressing it right at the inception.   

Design thinking for product life improvement 

The design thinking process for product life improvement is a user-centric process. It involves redesigning plastic packaging to better its usage for consumers while making it more environment friendly. 

We do this in two ways, one reduce plastic in the design stage by light weighting or by redesigning to reduce eliminable packaging components and two improve the design to extend the useful life of the product, reducing the waste going to the landfills. 

An example of our commercial plastic waste reduction-oriented design projects is the Protective Ring on Kinley 20-liter bottles. 

The Kinley Protective Ring 

The protective ring was a design conceptualized and tested in collaboration with Kinley. Kinley water exemplifies purity. The task at hand was to improve the life of their 20 liter bottles and protect them from deformity caused due to rough handling by transporters through the multiple cycles of usage. The design of the protective ring around the shoulder and the base of the bottle was therefore conceptualized to embody ease of use. We also wanted to help Kinley deliver their sustainability promise. 

The resulting ring was injection molded in HDPE material to provide sturdiness and was designed in a manner that it fits snuggly to the shoulder and base of the 20 liter bottles, making it sturdier for the transporter to roll the bottles when they load and unload it on their vehicles, for multiple cycles of usage. The HDPE material design makes the ring easily recyclable once it reaches its end-of-life. The finished look of the ring in blue color reflects Kinley’s brand presence. 

Redesigning packaging for a lighter footprint 

We have taken multiple plastic reduction projects in our 40 years plus of existence. Light weighting of packaging is one of our most actively followed plastic reduction efforts. Our unique designs towards light-weighting are already proven like Super Shot Neck Jars/Caps is our patented design. We have introduced lightweight preforms with reduced neck height, that reduced the weight of the finished preform by 1.4 grams while maintaining the same blow ratio. 

Technologically we have tested production of packaging using modern material science like the Foaming Technology. The foaming technology reduces the weight of containers by upto 20 percent depending on the application, while maintaining the same barrier properties and tensile strength. Our advanced, lightweight plastics used in multiple products leave a lighter footprint. 

Conclusion 

With our extensive experience in converting plastics and borrowing from the various industry researches, we conclude that when compared to alternatives, the environmental cost of using plastics is nearly four times less than the costs of other materials. Switching out plastics in consumer products and packaging with alternatives that perform the same function would increase environmental costs from $139 billion to approximately $533 billion annually as identified from a recent life-cycle analysis by the ’America’s Plastic Makers Alliance’. 

In addition to expanding ways to recover and repurpose plastics, design changes can further reduce the environmental footprint of plastic packaging. Plastics and plastic packaging play a far more positive role in the quest for sustainability than most people recognize. Design thinking for plastic reduction is our responsibility as packagers to make this universal material, environmentally sustainable. 

Food loss and waste has become crucial across the globe. A study by Food and Agriculture organisation of United Nations found that roughly one-third of food produced for human consumption is lost or wasted globally, which amounts to about 1.3 billion tons per year. The carbon and water footprint of this significant amount of food loss and waste was estimated to be 4.4 gigatons (or 8% of the world’s total CO2 equivalent and 250 km of blue water, respectively). 

The study also found that food loss at the retail level is a rising cause of concern in urban food consumer markets. Studies reveal that the wastage levels are between 24% to 40% in the food supply. The major cause of food wastage at the retail level is attributed to poor packaging, improper storage, incorrect temperature control, and loss in transport. This loss combined with the wastage at the consumer level caused mainly due to lack of awareness on shelf-life / best by dates, inadequate pack sizes, improper storage once the pack has opened, forms a major chunk of the food loss percentage. 

As a packager with a legacy of offering premium quality environment friendly packaging to multiple FMCG companies across the globe, Manjushree is uniquely placed to innovate and develop new packaging, collaborate with other stakeholders on the waste management challenge and inform consumers in order to increase their participation. 

Finding the right solution, one that not only ensures food freshness and safety but also protects taste, aroma, and appearance, while being environmentally conscious is not easy. Each product is different and the journey the food takes from the origin to shelf must be considered. There are several packaging opportunities like – using packaging with barrier properties, introducing reusable packaging range, providing sustainable pack sizes etc., that provide a harmonious solution to contain and control the challenges at both the retail and consumer level. 

Here are four packaging suggestions to reduce food waste at the retail stage. 

1. Introduce serve size, small packaging

Serve size packaging are multi-baggers, they have the potential to transform consumption patterns. They stock more for less space in a retail outlet, induce repeat purchase with their single-serve size product quantity, reduce post-consumption wastage – reduced quantity leaves less excess, and have a smaller environmental footprint as their manufacturing and transport requires reduced resources on a per-piece basis. 

2. Choose the right product packaging mix

Every food item has its unique storage requirements. Food loss at retail can be controlled by selecting a packaging that is conscious of its product’s need of temperature and light sensitivity, barrier requirements, and environment resistance to ensure freshness of food for long. Customised packaging ensures a safe origin-to-cart journey of the food product. 

3. Opt for bio-degradable thin wall containers

Cut fruits, vegetables, baked produce, etc., at retail stores have small shelf life and are traditionally packed in flexible packaging to make it cash-and-carry friendly, but once opened, storing these items become difficult. Bio-degradable, thin-wall containers are an excellent alternative for packaging these perishables. They store the food product till its useful life and dissolve into the elements once it is discarded. 

4. Encourage reusable packaging

Sustainability does not only come from recycling, encouraging reuse increases the lifecycle of plastic packaging by keeping it in consumption for longer. In the food and beverage industry, a lot of waste occurs due to improper storage of a product after the pack has been opened. Moving to reusable rigid packaging not just gives safe storage to the primary product but can also be used to store other perishable after the primary product is fully consumed. In a regular household, rigid plastic containers have far more opportunities to be reused than flexible packs. 

Sustainable Pack Sizes 

Offering sustainable pack sizes aim at source reduction by providing smaller packaging options that bring evident benefits at both the retail and consumer end of the supply chain. At retail, smaller pack sizes are easier to store, ensuring more for less in stock space. Smaller pack sizes have a reduced footprint since they consume less plastic and production resources and contribute lesser to carbon emissions caused during transport. 

At the consumer end the benefits of having smaller pack sizes is similar, it is easier for them to store and consume quicker than larger pack sizes leading to reduced wastage. It is especially beneficial for high shelf life products that generally have a smaller consumption life once opened, for example – dairy products, freezer food, dairy-based drinks, juices etc. 

We believe choosing serving size packages and smaller package options is a smart solution. Here is an example of our serving size packaging design for the Beverage industry. 

Depicted above are recyclable PP bottles with recyclable HDPE caps that offer fill volumes of 180ml, 200ml and 300ml. The bottles are designed with 38mm neck for a spill-proof gulp. The bottles come in unique designs with customisation options. These PP bottles are semi-transparent, easy to stack and handle. They have a high tolerance for retort sterilization up to 121-degree Celsius for 20 mins and can tolerate both conduction & induction sealing. These bottles offer a shelf life of up to four months 

We also manufacture PET preforms for small 180ml, 200ml, and 300ml size beverage bottles. These bottles offer stability for aseptic environment filling and are available with a tamper-evident screw cap. They offer a shelf life of up to 90 days. 

Over the years we have undertaken multiple redesign and resizing projects. If you are in need of a fresh look for your product, or want to optimise your existing packaging, we can help you with your next sustainability project, contact us at – info@manjushreeindia.com. 

What are some types of modified atmosphere packaging?

• • 1. Gas flushing

One of the most popular active modified atmosphere packaging
technologies for food and beverage products, gas flushing of
packages is very common. Gas flush accomplishes three things:

• • 2. Displacement of oxygen to delay oxidation
  • 3. Decreasing the growth of aerobic spoilage organisms
  • 4. Acting as a filler to maintain package conformity
  • 5. During a gas flush process, a harmless gas, usually nitrogen is
    actively pumped into the packaging before sealing to displace
    ambient oxygen. This is done to decrease the amount of oxygen
    inside the package, which will in turn decrease the rate of
    spoilage, as oxygen is one of the top killers of freshness.
  • 2. Barrier packaging material

Choosing specific packaging films that provide increased
protection is an example of passive modified atmosphere packaging.
This is accomplished by using barrier packaging materials that
provide decreased permeability to moisture and oxygen, such as
low-density polyethylene (LDPE), High-density polyethylene (HDPE)
or polypropylene (PP). Oxidation prone products like sauces, also
use multi-layer (up-to six layers) packaging. The central layer in
these multi-layer materials are mostly of EVOH. EVOH is a
flexible, crystal clear, and glossy thermoplastic copolymer that
has some of the best barrier properties to gases such as oxygen,
nitrogen, and carbon dioxide making it especially well-suited for
packaging of food, drugs, cosmetics, and other perishable or
delicate products to extend shelf life.

• • 3. Scavenger or desiccant packs

Another example of MAP packaging is the addition of an oxygen
scavenger or desiccant pack to your packaging. you have probably
seen these inside pill bottles.These small sachet type packages
often contain a mixture of iron powder and ascorbic acid, and
sometimes activated carbon. These ingredients act as catalysts or
activators, absorbing ambient moisture and oxygen, thereby
removing it from the interior of the packaging that houses the
perishable product.

How does modified atmosphere packaging protect food?

Largely, modified atmosphere packaging technologies protect fresh
food by decreasing its exposure to oxygen. Oxygen leads to
oxidation, which can cause discoloration, spoilage, and off-flavors
and textures. By decreasing or controlling the amount of oxygen
present in a package, the food product remains fresher longer, gets
an extended shelf life that ensures it remains attractive to
consumers.

Modified Atmosphere Packaging became especially important during the
COVID-19 outbreak of 2020. Consumers were instructed to social
distance themselves and stay at homes as much as possible, so many
began stocking up on food products with longer shelf lives. As a
result, food producers and packagers saw enormous increases in
demand for packaged food products that used MAP packaging
technologies. Want to know how you can extend the shelf life of your
products? Write to us on info@manjushreeindia.com.

Light weighting is a sustainable practice that aims at maintaining the life cycle of inventory while reducing its carbon footprint by limiting the usage of plastic. It is a process by which the existing packaging is adjusted and redesigned to reduce the overall weight of the item. Light weighting is done by innovations in materials, like replacing packaging material with a lighter weight alternative as done using the foaming technology or cutting down the amount of packaging material by redesigning the packaging.

A recent innovation in light-weighting is foaming technology. Foaming is a process that is accomplished by controlled infusion of inert gases like CO2/N2 etc in a suitable layer of polyolefins. This allows overall reduction of the density of the plastic material and hence lighter weight.  Following the principles of light-weighting, at Manjushree we have been able to achieve a weight reduction of up to 20% for one of our malt-based health drink supplements manufacturing clients.

Redesigning is another technique to achieve light-weighting. We have been proactively offering light-weighting solutions through various design innovations to our customers over the history of our association with them. Our unique designs towards light-weighting are already proven like Super Short Neck Jars/Caps is one of the patents. We have recently introduced the Neck Support Ring (NSR) which will enable to reduce the weight of the Bottle/Cap and a couple of patents are in pipeline especially towards Light weighting plus tamper-evident features. For some of our beverage customers, we have achieved lighter weight up to 34% in PET by reducing the wall thickness or thin walling the packaging design.

Frequently asked questions

Light-weighting of PET, how can it be done?

Light-weighting of PET can be achieved by redesigning packaging material to reduce the weight without compromising its quality. The redesigning can be simple like replacing handles with grips within the packaging design to hold a container. Light weighting in PET can also be achieved by thin walling of containers to reduce material used.

How can the redesigning technique be achieved?

Design is critical and each material type has its own challenges. There are several factors we keep in mind while redesigning packaging – For example, in PET beverage bottles/containers, the redesigning is achieved by following some of these techniques

1. a)Introduction of technical ribs in the right places to maintain top load with lower wall thicknesses
2. b)Reducing weight in necks where no internal gas pressures are involved
3. c)By redesigning the shape of the container /bottle
4. d)By using higher I.V. resins wherever possible

It is also important to consider the filling operations of the packaging. If the bottles are filled using ‘Jet Stream’ air systems which work with neck handling, then the bottles must have a special space below the lowest part of the neck to transport the bottles in the filling line.

Labeling is another important element to consider in a light-weighting project. If a thin-walled bottle is labeled before filling, it is more flexible, making labeling difficult and inaccurate. It is therefore important that light-weighted bottles especially the ones that are thin-walled should be labeled after the filling.

Is Manjushree exploring light-weighting for PET products?

We have been proactively offering light-weighting solutions through various design innovations to our customers. We have done design innovations like thin walling for water bottles, replacing handles with in-mold grips for efficient handling of milk jars/bottles apart from various super short neck jars made for different customers.

Chat with us to know more about our sustainability projects.