Resources / Custom Sustainable Packaging

Sustainable Packaging: Reducing Plastic Waste with Smart Solutions

Environmental issues are a top priority in today's world. The increasing environmental awareness is driving the demand for more sustainable packaging solutions, requiring businesses to find ways to minimize waste, use recycled materials, and reduce the carbon footprint of their packaging. Every business decision we make has a significant effect on the environment. The way we package our items is one important area where our decisions can have a big impact. It is not only a responsible choice to switch from conventional packaging, particularly single-use plastics, to more sustainable options, but it is also a necessary step towards creating a healthier and more environmentally conscious future.

Packaging is a constant presence, no matter what product we are discussing. From a sustainability standpoint, this presents a significant challenge: How can we make sure that packaging fulfills its function while minimizing environmental impact as much as possible? This question presents a major challenge for us at Green Field. Here, we want to show you how we're working to tackle it.

The packaging plays a critical role in product presentation, protection, and brand identity. Packaging presents a significant challenge for us as it must fulfill various requirements and serve multiple functions, including sustainability concerns, cost efficiency, supply chain disruptions, regulatory compliance, and the need to balance product protection with aesthetic appeal. At the same time, we're committed to keeping sustainability in mind while addressing these demands and striving to make our packaging as environmentally friendly as possible.

The continued use of single-use plastic in polybags remains a significant sustainability concern, especially considering that 95% of plastic packaging worldwide isn't recycled or reused.

Unfortunately, we haven't found a plastic-free alternative that meets all the necessary criteria. So, we're still reply on plastic bags. Even bioplastic bags aren't a perfect solution. While they're theoretically biodegradable, they typically break down only in industrial composting facilities, not in natural environments.

Packaging is necessary to protect products during transportation, handing and storage, preserve their quality, and provide information to consumers. It also plays a crucial role in branding and marketing, helping products stand out on shelves. Packaging can make products easier to store, transport, and use, and may include features like resealable closures or easy-open mechanisms.

Sales packaging consists of all components that are directly associated with the product that are disposed of by the consumer. These serve specific functions; here's a brief overview of what they're good for.

The hangtags on our products enable us to share important product details with our customers. They also feature barcodes essential for logistics and sales processes. So, hangtags serve a dual purpose: serving as a communication and marketing tool while facilitating logistics operations.

Polybags, the plastic bags in which the product is wrapped when you order and have it delivered to your home, unfortunately remain necessary. To maintain product quality during long transportation routes-from the production site to the logistics warehouse, then to the store or customer-it's crucial to shield them from moisture, mold, and dirt, which these bags accomplish. However, their use isn't solely for protection; they also aid freight companies and warehouse logistics by providing a convenient surface for adhesive barcode labels, preventing damage to products in storage. Additionally, these bags provide a convenient surface for adhesive barcode labels, which helps prevent damage during storage, and many retailers require individual packaging for easier handling in their processes.

Shipping packaging, like the cardboard box used to ship a product ordered online from us, is clear: The primary purpose of shipping packaging is to ensure that the product arrives at your doorstep intact.

Transport packaging includes all packaging components used for shipping, such as shipping cartons, strapping bands, pallets, reusable transport boxes, and more. The primary purpose of transport packaging is straightforward: it is essential for moving products from one location to another-specifically, from the production site to the warehouse and then to the retailer-while protecting them from moisture, dirt, and potential theft.

At present, we are actively balancing performance, sustainability, and cost-effectiveness in our packaging choices. While we have made significant progress in minimizing plastic use and optimizing design, we still face limitations due to the availability and practicality of certain eco-friendly materials -particularly when it comes to durability, waterproofing, and cost parity with conventional plastic-based packaging.

For now, some of our packaging still relies on plastic, especially when alternatives are not yet suitable for protecting products during shipping or maintaining visual quality. However, we are fully committed to reducing our environmental footprint and are continuously researching better solutions.

The careful selection of materials is a crucial aspect of environmentally responsible packaging. Businesses can significantly lower their environmental impact by utilizing products that are recyclable, biodegradable, or sourced from renewable resources. Among the sustainable material options are:

1. Bioplastics

Bioplastics are created from renewable resources such as algae, cornstarch, and sugarcane. They serve as a great alternative to conventional plastics, which are made from fossil fuels. Bioplastics can be recyclable or compostable and have a lower carbon footprint compared to traditional plastics derived from fossil fuels. While bioplastics can help reduce the reliance on fossil fuels and lower greenhouse gas emissions, their environmental benefits vary based on production and disposal methods. Some bioplastics require specific conditions to break down, and cultivating the raw materials can impact food supply and land use. Therefore, it is important to assess their sustainability before widespread implementation. By choosing bioplastics, you can significantly decrease your dependence on non-renewable resources and contribute to a more sustainable packaging industry. Check out the Business Insider video below to learn how plastic can be made from seaweed.

2. Recycled Plastic

Recycled plastic is another environmentally friendly packaging option. Recycling plastic helps conserve energy, reduce greenhouse gas emissions, and decrease the need for new petroleum extraction. It also lessens the amount of waste going to landfills and the plastic that ends up in the environment, including our oceans. However, not all plastics can be recycled. The recycling process, which involves collecting, sorting, and reprocessing materials, can be challenging and costly. Additionally, after several recycling cycles, the quality and integrity of plastic may deteriorate, limiting its use in certain applications. Despite these challenges, recycled plastic plays a crucial role in the circular economy by extending the useful life of materials and reducing the overall environmental impact of plastic use and production. Recycling and reusing are vital for the future of our waters and our environment.

3. Paper and Cardboard

Kraft Paper and cardboard are often considered more sustainable alternatives to plastic packaging due to their biodegradability and recyclability. They can be composted and are primarily made from renewable resources, such as wood pulp, allowing them to decompose much faster than plastics and resulting in a smaller environmental footprint. The established recycling processes for cardboard and paper conserve energy, reduce greenhouse gas emissions, and significantly decrease the need for virgin materials. To maximize their environmental benefits, it is essential to source paper and cardboard from certified sustainable companies and to recycle them properly after use. When managed appropriately, these materials can serve as effective packaging options that minimize environmental impact.

4. Compostable Materials

Compostable materials, such as plant-based plastics and natural fibers, provide an innovative solution to packaging waste. These materials can break down naturally without harming the environment and help create nutrient-rich compost. They are renewable and often have a lower carbon footprint than conventional plastics because they are derived from plant-based sources like corn starch, sugarcane, or potato starch. By adopting compostable packaging, businesses can reduce landfill waste and support a more sustainable waste management system. The main advantage of compostable materials is their ability, under the right conditions, to decompose into healthy compost that improves soil quality and minimizes waste sent to landfills. Proper disposal is crucial for their environmental effectiveness, and specific conditions must be met for compostable materials to break down. Not all regions have the necessary infrastructure to manage them properly. Therefore, understanding the composting process is essential for realizing their full environmental benefits. It's important to note the distinction between biodegradable and compostable materials: while all compostable items are biodegradable, not all biodegradable items decompose to the same extent or in the same way.

In the recently year, we've seen a decrease in the amount of packaging made from paper/cardboard, but a slight uptick in plastic packaging. This is partly due to selling fewer products, but also because we're continually refining our data collection methods to better track our packaging quantities.
 

On a positive note, there's been a significant increase this year in the use of packaging made from GRS/RCS certified recycled plastic. This uptick is thanks to improved data accuracy and our ongoing switch to designated polybags crafted from recycled plastic. Not only does this approach conserve resources, but it also helps us reduce emissions from packaging. However, this transition hasn't been without its challenges: higher costs, minimum order quantities that sometimes necessitate the use of slightly larger bags, and other obstacles along the way.

One way we aim to reduce the footprint of our packaging is by further transitioning to polybags made from recycled materials. These are already being used for our bags, and this year, the planned transition will extend to our other product ranges.
 

Our new plastic packaging (polybags) made from recycled material are derived from used plastic packaging - what's known as 'post-consumer' recycled material. This allows us to partially close the loop on the raw material cycle, conserving resources and reducing the CO2 footprint of our packaging. To ensure this, the new polybags are certified by RCS or GRS.

Green Field has contributed to the development of the Polybag Standard, which provides best practice guidelines for plastic bag use. Our goal is for all polybags we use to fall into the "green" category.

In addition, we are pursuing other approaches to reduce our emissions from packaging, focusing on packaging reduction. For example, we are exploring new folding techniques to pack products into smaller bags and save materials. So far, the tests have been promising, but one issue is that the products often have wrinkles. We are continuing to work on solving this problem.

To move towards more sustainable packaging beyond just reducing single-use plastic, businesses and consumers can adopt a variety of strategies. These include utilizing recycled materials, switching to biodegradable or compostable alternatives, and implementing reusable packaging systems. Additionally, focusing on reducing waste and promoting circularity through strategies like chemical recycling and innovative packaging designs can help minimize the overall environmental impact of packaging.