Sustainable packaging - A win-win for your supply chain, and the planet

Key takeaways:

1. The packaging industry has been a long-standing offender in the planet’s plastic crises, accounting for nearly 40% of total plastic usage.

2. Sustainable alternatives to toxic polystyrene, like waste wool and mycelium, offer several supply chain benefits, from reducing costs and emissions to boosting brand reputation.

3. Switching to new packaging materials can be easy if you adopt a collaborative and phased approach.?

---------------------

From protecting a product to making it look good, packaging's role in supply chain success can never be overemphasised. Sadly, the packaging industry also happens to be a major offender in the planet’s plastic waste crisis.

With the rise of the environmentally-conscious consumer, the time has come to draw the curtains on single-use packaging solutions. Don’t think of it as a compromise, as adopting sustainability in packaging will deliver benefits for every player along the supply chain.?

As the founder of a cold chain packaging company, I’ve got plenty of real-world examples that showcase the many ways innovative sustainable packaging can future-proof a business.?

Read on as I make my case for using sustainable packaging in supply chain and logistics.?

Understanding sustainable packaging

About 40% of plastic produced is used up in packaging. In fact, most of it is used only once before being thrown away. The alternative is clear: sustainable packaging.

Unlike single-use plastics, sustainable packaging is made from materials that can be reused again and again without much dip in quality. They’re also recyclable and degrade easily without leaving behind any toxic residue. What’s more, they’re made using renewable resources that can be replenished or regenerated.?

Benefits of sustainable packaging in the supply chain

What comes to mind when you think of the word ‘packaging’? A box, a carton, or a wrapper?

Well, it’s so much more than that. Packaging is a system that impacts a product’s handling, transportation, supply chain costs and emissions, among other factors. That’s why companies are always chasing after a cost-efficient and resource-optimised packaging solution.?

If a high-performing supply chain is what you’re after, sustainable packaging has lots to offer:

Reduced supply chain costs

The right packaging innovation can significantly cut down both material sourcing as well as shipping costs. For example, at Planet Protector, we flat-pack WOOLPACK solutions, including compressing wool liners to about half of their original size. This has resulted in up to 80% savings on storage, transport, and unloading costs compared to a similar volume of polystyrene boxes. On top of that, our wool packaging is quick and easy to assemble, reducing labour and handling costs at every step of the supply chain.?

Optimises resources and reduces emissions

Changing consumer sentiments have led to 2.7 times faster growth in sustainable products compared to their traditional counterparts. So, you’ll have no trouble finding packaging that is lighter and can be tailored to maximise space utilisation in comparison to your current solutions. With reduced space requirements, you’ll need a lesser number of shipments. This will bring down waste and transport-related emissions generated by your supply chain.?

Attracts eco-conscious consumers

Sustainable packaging may not yet be the norm, but it’s key to winning over the new, environmentally-conscious consumer. Notice how governments have also started responding to these sentiments and bringing in strict regulations to fight plastic pollution. A business that actively seeks opportunities to incorporate sustainability will always be a step ahead of others and find it easy to grow a loyal base.?

Alternatives to polystyrene

Granted, single-use packaging, such as those made from expanded polystyrene (EPS), is cheap, but it comes at a massive cost to the environment and human health. Thankfully, there are plenty of innovative packaging solutions that perform better and add up to be more economical in the long run. I discuss two of my favourites below:?

Wool

One of the reasons polystyrene got so popular was its excellent insulation and cushioning qualities. Wool, on the other hand, has been here since the beginning of time! All it takes is looking into nature to find alternatives. Sustainable alternatives made from waste wool, like WOOLPACK, boast superior temperature-regulating properties, which means less need for refrigerant during transit. This has delivered substantial cost and energy savings for many of our clients. Plus, our recent Life Cycle Analysis shows that WOOLPACK has a 41% lower carbon footprint than polystyrene.

Wool fibres also match up to polystyrene’s cushioning properties. Their high natural elasticity makes them ideal for protecting delicate objects during transit. All these reasons are why WOOLPACK liners, pouches, and films are fast becoming the packaging of choice for foods and pharmaceuticals.?

Mycelium

This sustainable alternative is derived from the mycelium -? the interconnected fibrous root network of the fungi that can turn into a strong, durable mass. Because it's a self-growing biomaterial, you can mould mycelium into any shape or size. To transform mycelium into a packaging material, manufacturers rely on agricultural waste, such as wood chips and hemp curd. Ecovative is a well-known name in this space, offering rigid as well as flexible mycelium-based packaging solutions.?

Unlike EPS, mycelium-based packaging is made from a renewable natural resource. It’s easy to grow, even at an industrial scale, and it doesn’t require nearly as much water and energy as EPS. Thanks to a porous structure, this packaging gives a tough fight to polystyrene in temperature regulating abilities. Since it’s a novel technology, mycelium-based alternatives are more expensive, but startups like Ecovative are well on their way to making them cheaper and more accessible.

Adopting new packaging materials

Changing the status quo, especially something as crucial to a supply chain's success as packaging, can be overwhelming. But trust me when I say this: it’s much easier than you think. Here are some tips that have helped our clients make the transition a smoother process:

Assess current packaging: Make the best of what you have. You may not need to switch if you can lower the footprint of your current packaging. Identify opportunities to cut down on secondary and tertiary packaging like large cardboard boxes and pallets wherever possible.?

Take a long-term view: After cutting down on needless packaging and overuse, you’ll have a better estimate of your actual packaging needs. Most people think sustainable packaging is expensive. Well, upfront costs may make you feel that way, but it’s crucial to take a long-term view. Look at the total cost by factoring in transport efficiencies, reduced supply chain costs, and competitive advantages.

Review your suppliers: Incorporate the latest trends and industry best practices to optimise packaging design for less material use and waste. You can also rely on your packaging supplier for such insights. I’ll provide an example of one of our early adopter clients. When they reached out, they were struggling with the bulky polystyrene, which was cramping their warehouse and increasing logistical costs. On top of that, the material had a heavy carbon footprint and was especially tricky to dispose of.?

The only reason they were sticking to it was because of its insulation capabilities, which allowed their samples to stay in a 2-8°C range. We quickly designed and customised WOOLPACK to fit their products, freeing up 80% of space and lowering incoming freight costs by 66%. They now needed fewer trucks to transport and could dispose of packaging through recycling or composting. All this without compromising on temperature stability or protection.

Adopt a phased approach: When you’re switching to sustainable packaging in your supply chain, it’s a huge step. You can overcome bottlenecks by rolling out changes in stages instead of all at once. Do trial runs and pilot projects to test sustainable alternatives. This will make it easier to get buy-in from your stakeholders.

Speaking of stakeholders— you’ll need a few change management tricks up your sleeve to avoid pushback. More on this below.?

Change management in packaging transition

One reason why RCPA stuck to polystyrene despite all its disadvantages was because of the pharmaceutical industry’s aversion to change. Not just pharma, when it comes to embracing a sustainable solution, you may find yourself jumping through hoops to get stakeholders on board. Improve awareness of sustainability packaging through cross-functional collaboration and training programs.?

Making sure everyone from the product development to the marketing team is on the same page will drive change throughout the organisation. Having well-defined sustainability metrics and linking them to goals and incentives will make matters easier. Be transparent in your messaging and back it up with data such as results from packaging trials to engage stakeholders on your agenda.

Final thoughts

Unlike toxic and non-compostable polystyrene, sustainable packaging has a significantly lighter impact on the environment. It relies on materials that are reusable, recyclable, or made using renewable resources. Most sustainable packaging also degrades quickly, returning to nature faster than any type of plastic ever would.

If you’re looking for packaging that can optimise logistics, reduce costs, and attract environmentally-conscious consumers, reach out to Planet Protector today .