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Waste Management (A Packaging Perspective)

Waste Management (A Packaging Perspective). Colm Munnelly Packaging Technologist Irish Biscuits Ltd. December 2002. Who are Irish Biscuits?. IBL formed in 1966 by merger of Jacobs (1851) and Bolands Biscuits (1957) Employ over 600 people Manufacture over 50 types of biscuit

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Waste Management (A Packaging Perspective)

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  1. Waste Management(A Packaging Perspective) Colm Munnelly Packaging Technologist Irish Biscuits Ltd. December 2002

  2. Who are Irish Biscuits? • IBL formed in 1966 by merger of Jacobs (1851) and Bolands Biscuits (1957) • Employ over 600 people • Manufacture over 50 types of biscuit • Turnover circa 100,000,000 euro

  3. Packaging Waste legislation • Waste Management (Packaging) Regulations 1997: (“Designed to assist and promote the recycling of packaging waste” -SDCC) • Two Real Options: • 1. Comply with the legislation independently and report to the local authority. • 2. Participate in a Waste recovery scheme operated by an approved body (Repak)

  4. 1. Legislation Requirements: • Provide information on annual turnover • Provide information on location of premises • Provide information on weights of packaging materials • Display notices • Provide facilities to accept, collect packaging waste • Return waste to suppliers • Recover or make waste available for recovery • Prepare, publish plans and reports • Submit information monthly to local authority

  5. 2. Obligations of Repak Membership: • Provide data on packaging material twice a year to Repak • Pay invoices • Join Green Dot scheme • Deal responsibly with waste • Inform Repak of changes to systems • Allow system to be audited for Repak

  6. Advantages of Repak Membership: • Obligations complied with as a group • Green Dot membership • Approved Contractor Scheme (Rebates) • Audit chain for each contractor

  7. Sources of Physical Waste at IBL • Food Waste • Dough • Dry Biscuits • Processed Biscuits (with Cream/Chocolate/Mallow) • Packaging Waste • Input Packaging • Output Packaging • WIP (Work in Progress)

  8. Sources of Packaging Waste • Goods Inwards • Bulk Material • Palletised Ingredients • Minor Ingredients • Packaging • Factory Produced • Input Packaging • Output Packaging • Warehouse / Shipping • Pallets • Stretchwrap

  9. Packaging Material Types • Cardboard Corrugate, Cartonboard etc. • Paper Liners, Inserts, Menu Pads • Flexible Plastic Film Wrapper Reels • Other Plastic Tubs, Trays • Metal Tins • Glass Bottles • Wood Pallets

  10. Waste Hierarchy Reduction / Minimisation Re-use Re-cycle Reclaim Landfill

  11. 1. Reduction / Minimisation • 1. Reduction of input packaging • 2. Gauge reduction on film, trays, tins, tub • 3. Reduction of outer case board grades • 4. Increased number of packs per outer case • 5. Pallet volume optimisation

  12. 2. Re-use • Returnable containers for trays, tubs • Increased use of Recycled (Test) board in outer cases • Maximum usage of pallets (Increased use of CHEP)(wooden for goods outward) (plastic on factory floor)

  13. 3. Re-cycle • Corrugated Cardboard Smurfit Re-cycling • Cartonboard Smurfit Re-cycling • Flexible film Dilloan Recycling • Other plastic Re-Tech Processing/Dilloan • Metal Hammond Lane • Glass (Negligible amounts) • Wood Pallet Services

  14. 4. Reclaim • Awaiting options for incineration • Input packaging on colours/flavours • Removal of pvc and pvdc material

  15. 5. Landfill • Compacted, unsegregated waste from the factory floor goes to landfill through Ipodec • Any material left that does not have a re-cycling option is landfilled. • Cost of landfill (Direct and Indirect)

  16. Internal Packaging Waste

  17. ‘Repak Member of the Year’ • Packaging waste considered at product design stage • Emphasis on Reduction and Re-use • Sourced re-cycling options for all of our packaging materials • Encouraged contractors to join subsidy scheme • Reduced tonnage to landfill by 10% in 2001

  18. Packaging Fees

  19. What winning has meant to IBL • Turns Repak into something positive • Recognition for past efforts • Establishes momentum • Helps overcome ‘difficult’areas • Helps publicise re-cycling efforts throughout the company.

  20. Future plans in IBL • Further investment in bailing/compacting • Roll out of recycling to more ‘difficult’ areas • Design for recoverable/recyclable packaging • Holistic projects • Less input packaging • Optimum product in packets • Optimum packets in cases • Optimum cases on pallets

  21. Challenges • Options to recycle in Ireland and to market recycled product in Ireland. • Current weight based system does not allow for mixes of virgin/recycled material. • Recycled material does not mean cheaper material. • Conflict between marketing concerns and environmental concerns.

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