Flexible Packaging: Better Packaging Better World

By Assunta Camilo, Simone Ruiz, Margaret Hayasaki and 4 more

Flexible packaging: the fastest growing packaging market in the world is the subject of the new book by Instituto de Embalagens

In Brazil, the performance of the flexible packaging industry also continues to expand. In 2021, gross sales reached BRL 43.6 billion, according to a Maxiquim study carried out for ABIEF (Brazilian Association of the Flexible Plastic Packaging Industry). The result represents growth of more than 55% in relation to the previous year.

The food industry remains the main market for flexible plastic packaging in Brazil (42% share) and globally (75.5%) in 2021. The fastest-growing end-use markets include meat, fish and poultry, and frozen foods, with an average annual growth rate of 5.9% globally.

Flexibility, as the name implies, is one of the great differentials of flexible packaging that is present in various categories of consumer products, addressing convenience, practicality, safety, and environmental, economic, and social sustainability. The growth of stand-up pouches around the world and in Brazil is notable, adding lids and accessories, and gaining market share in new segments. "Innovation brings an avenue of opportunities to develop better flexible packaging for a better world", highlights Assunta Napolitano Camilo, director of the Packaging Institute.

Sustainability - The Smithers study also points out that revisiting various stages of the packaging journey, from design to recycling, will be important for the circularity of plastic and will also be one of the subjects addressed in the new bilingual book on Flexible Packaging by the Instituto de Embalagens.

In Western Europe, there is increasing pressure to replace difficult-to-recycle plastics in many important applications. This is already driving the evolution of flexible paper packaging and, in particular, structures that can provide adequate barrier protection. Alternatives under development within plastics include:

• Use of more recycled plastic content without compromising material performance;
• Improve the recyclability of current packaging options with more mono-material constructions;
• Identification of suitable markets for flexible biopolymers.

An emerging trend in the post-Covid world has been the use of refill packs for household and personal care products. This has unlocked new potential for flexible plastic refill packaging that minimizes size and weight in transit.

The new bilingual book on Flexible Packaging brings updated content, covering, market information, trends, design, innovations, processes, equipment, and sustainability.

• Language: English
• Publisher: Instituto de Embalagens LTDA
• Release date: Dec 1, 2022
• ISBN: 9788561409173

Book preview

cover.jpg

INSTITUTO DE EMBALAGENS LTDA.

Calçada dos Tagetes, 23

06453-043 – Barueri - SP – Brasil

www.institutodeembalagens.com.br

Flexible Packaging

Barueri - São Paulo: Instituto de Embalagens, 2022.

ISBN: 978-65--990455-9-2

Project: FuturePack Consultoria de Embalagens

General Direction: Assunta Napolitano Camilo

Coordination: Simone Ruiz

Research: FuturePack Consultoria de Embalagens

Text Editing: Margaret Hayasaki

Revision: Letícia Carniello

Translation: Several

Proofreading: Fernanda Biagio and others.

Publishing and Graphic Design: Edenilson Santos and Ana Claudia Martins

Cover: Edenilson Santos - FuturePack Consultoria de Embalagens

Photos: Edenilson Santos and Edicarlos Barretos (Cover)

International Data for Cataloging Publication

(CIP) (Brazilian Book Chamber, Brazil)

Flexible packaging : better packaging better world / [organization Assunta Camilo]. -- 2. ed. --Barueri : Instituto de Embalagens, 2022.

Ed. english.

Several translators.

ISBN 978-65-990455-9-2

1. Food - Packaging 2. Packaging - Environmental aspects 3. Packaging - Design 4. Packaging - Recycling 5. Packaging - Industry - Technological innovations

6. Plastics in packaging 7. Sustainability I. Camilo, Assunta. II.

Title: Flexible packaging : better packaging better world.

22-124838 CDD-668.4

Indexes for systematic catalog:

1. Plastic packaging : Technology 668.4

Eliete Marques da Silva - Bibliotecária - CRB-8/9380

Year: 2022

Execution: Instituto de Embalagens. All rights reserved.

Views and statements contained in the text are those of their authors and do not necessarily reflect the opinion of Instituto de Embalagens.

All of the images of this publication have the purpose of illustrating the concepts presented here in, being mostly responsibility of each author or contributor.

The credits of the images are found next to the Bibliographic References.

FuturePack, responsible for the graphic design of this work, made available his photographic and packaging collection to assist in the illustration and didactic of its content, made up of photos of points of sale, fairs and packaging bought in markets all over the world.

GRATEFULLNESS

At the end of another great and important project, the feeling that emerges is that of the most sincere gratitude. A genuine feeling of recognition for the dedication of each one in favor of collective work, with a desire to improve the world through knowledge.

A wonderful feeling of mission accomplished and of a great debt to those who believed in the project and made possible the publication of this book that is a valuable contribution to the flexible packaging sector.

I believe that we have to acknowledge every hand extended to us throughout our journey. Our careers and professional paths are built on peers and examples. We depend on other professionals who accompany us and guide us along our trajectory. These people are very important and deserve our gratitude.

Success is winning recognition and having dedicated professionals by your side, who inspire us and display their talents without expecting any retribution.

The union of the team - sponsors, supporters, authors, reviewers, designers and publisher - is the reason for the success of this book.

To all, my gratitude!

Better Packaging Better World

Assunta Napolitano Camilo

Instituto de Embalagens, Director

FLEXIBLE PACKAGING

As the population urbanizes, the need for packaging increases. Among all, flexible packaging is the fastest growing in the world. Demand for flexible packaging (paper, aluminum, and plastics) will reach 39.54 million tons by 2026, according to a report by Smithers.

The growth is mainly driven by the food segment, the main market for the application of flexible packaging. Also, to meet the demand for packaging refill of personal hygiene and cleaning products.

The expansion of flexible packaging is justified, since it is the option that offers an adequate barrier, besides being lighter, more efficient, and competitive. To compensate for these advantages, the flexible packaging industry, starting from its raw materials, needs to review its positions in relation to the issue of the Circular Economy.

Flexible packaging is less recycled because of all the difficulties from domestic sorting to the competitiveness of recycling.

The intention of this publication is to update the information about raw materials, processes, equipment. It is to present innovations, new opportunities, and some possible ways to improve this delicate relationship between flexible packaging and the environment.

The challenge is enormous, but so is science. It is important to clarify the situation and the awareness of the whole society, so that, together, we can address the solutions, which will be several. It is mandatory to start working for an effective circular economy for this type of packaging, that saves so much food, in a way that we can have:

Better Flexible Packaging, Better World.

Assunta Napolitano Camilo

Instituto de Embalagens, Director

"BETTER PACKAGING BETTER

WORLD" COLLECTION

There is only transformation from learning and knowledge

Aristotle

Sharing knowledge creates value in people’s lives. It is an altruistic practice that helps people not to stop learning. With this feeling, Instituto de Embalagens was founded in 2005. Its mission is to be the center of packaging knowledge in Brazil, contributing to the constant development of industry professionals.

We believe that, when professionals share knowledge about packaging in their workplace, they are collaborating with the development of better solutions so that companies remain active and competitive.

To support our studies, courses, meetings, training sessions and the packaging knowledge diffusion, we have decided to expand our didactic material by launching the bilingual book collection Better Packaging. Better World.

The collection has been launched in 2014 to improve the knowledge about packaging, in Brazil and abroad, offering materials that have become a reference to packaging professionals. We extended the invite to other authors beyond the Instituto de Embalagens’ professors with the goal of broadening the view and depth on many subjects. Since there we did eleven books, twenty-two in total.

The Better Packaging. Better World collection not only brings technical information, trends and innovation about the sector, but also highlights the characteristics of different types of packaging, indicating new applications and possibilities, processes and equipment, always addressing sustainability in an unbiased way.

In 2020, the year when the pandemic began, we republished the environmental education booklet: "Nós, as embalagens e o meio ambiente" (We, the packaging and the environment), aimed at children, and now we are delivering our 22th book.

So, with one more delivery, concrete attitude, we do:

Better Packaging Better World.

Assunta Napolitano Camilo

Instituto de Embalagens, Director

THE INSTITUTO DE EMBALAGENS

(PACKAGING INSTITUTE)

The Instituto de Embalagens is an institution dedicated to Packaging Teaching and Research, founded in 2005, and has become a center that generates content on packaging, in an impartial and unbiased way.

Its major contribution has been building bridges between the various players in the packaging universe, from basic industries to children, who are now so concerned about the planet. From manufacturers of raw materials, equipment, converters or transformers, brand owners, to recycling cooperatives. Always bringing those seeking information closer to those who have it.

During this period, IE had the support of more than 180 companies, 50 institutional supporters, national and international media, hundreds of executives, who were with us as speakers and as many other teachers, as instructors. Many have shared knowledge through articles and chapters for our 22 books and for the environmental education booklet.

The legacy built was always impartial and unbiased, which brought, in the various awards and recognition, most importantly, the trust of more than 15,000 professionals who sought us for retraining. With the participation of almost all packaging companies and brand owners in Brazil and, for some time now, also from abroad.

Among its initiatives, IE promotes courses and workshops on packaging, international trade fair panels and the Fórum Embalagem & Sustentabilidade / Packaging & Sustainability Forum, recognized as the most important space for serious discussion on the topic.

Since 2020, IE has also responded digitally, with courses transmitted from a distance, seeking to stay close and interactive through live broadcasts and hybrid moments (face-to-face and virtual). In addition to the production of e-books and, this year of audio book, to involve more professionals in the universe of packaging.

We want to continue as the center of knowledge on packaging in Brazil and for this, we have invited more and more professionals to be with us, in these very relevant discussions and initiatives, with the same purpose of doing what is right, what is true, so we will have more and more:

Better Packaging Better World.

Assunta Napolitano Camilo

Instituto de Embalagens, Director

PREFACE

Without packaging, without products

The pandemic simply proved what we already knew: packaging is extremely important to ensure the supply of products, especially essential items such as food, beverages, medicines, as well as hygiene and cleaning supplies. Specifically flexible plastic packaging increasingly fulfilled this role, replacing, with numerous advantages, some traditional packaging.

Lightness, flexibility of formats and volumes, potential for recycling, and use of recycled raw materials are just some of the attributes that have been recognized by brand owners and the final consumer. This is only possible thanks to the technological advances of the sector that are aligned with the new demands of consumption.

If we are expected to be 10 billion people in the world by 2050, flexible packaging will certainly have significant participation in this environment, ensuring speed and efficiency in delivering items that are essential to life and contributing to a more circular world. Today, packaging is already born sustainable because it is designed based on the circular economy model. With this, we have another fundamental point: the value of recycled material from post-consumer packaging. We have at our disposal valuable raw material that will give life to new packaging or other items that will be reinserted into the consumer chain.

The sustainability of packaging is consolidated as one of the main trends and will continue to guide consumer choices. The concept of sustainability has evolved and left the purely environmental area to embrace two other causes: governance and social. In other words, we are talking about ESG (environmental, social and governance).

Next to ESG expectations, the pandemic has put on the spotlight consumers used to online shopping and who expect the industry to deliver their purchases in packages compatible with the sales channel and product protection needs. Even though it is a B2B sector, the flexible packaging industry needs to learn to listen, deal, and communicate with this new, conscious, and much more demanding consumer. Then again, the flexibility of our packaging is an important differential.

Therefore, it is up to the industries to adapt to current demands and expectations and foresee future needs in order to remain competitive. And to do so, they need to continually update themselves and track the steps of markets and consumers, as well as incorporate technological and management innovation into their business.

May this book bring just that: knowledge and inspiration. Enjoy!

Rogério Mani

President of ABIEF (Brazilian Association of the Flexible

Plastic Packaging Industry)

PROJECT TEAM

ASSUNTA NAPOLITANO CAMILO

DIRECTOR OF THIS BOOK AND THE COLLECTION BETTER PACKAGING BETTER WORLD

Mechanical engineer from the São Paulo University (USP) Polytechnic School, in Brazil, with specialization in Industrial Administration from FCAV/USP and in Marketing from ESPM and Business School. Additionally, she attended other courses in the packaging area in Brazil and abroad and in addition to internships in Germany and in the United States. She has over 40 years of experience in the packaging market, with expertise in the areas of development, strategic planning, and business management, in companies such as Cyklop, DixieToga, TetraPak, and Ripasa. Also, as a writer and international speaker, she has covered themes such as packaging, trends and innovation, sustainability, among others. She has participated in major national and international events and fairs such as InterPack, K, Emballage, Chinaplas, Canton Fair, Tokyo Pack, Envase, Anuga, Drupa, Pack Expo, Drinktec, SIAL, ISM, Ambalaj, and Andina. She won several national and international awards, including Professional of the Year, in 2011, and the 2013 Embanews Brazilian Packaging Award. Currently, she is the Director of FuturePack and of the Instituto de Embalagens (Packaging Institute).

SIMONE RUIZ

COORDINATOR

Bachelor of Science in Industrial Chemistry from Faculdades Oswaldo Cruz, with a postgraduate degree in Sustainable Projects and Corporate Carbon Management by UFPR, MBA in Strategic Planning and Management by Uninter, and with several courses related to packaging in the USA and Europe. She has been working for almost 30 years in packaging projects, innovation, sustainability, research and development. She worked for companies such as Nestlé, Mondelēz and Antilhas Embalagens, in the areas of Packaging Research and Development, Quality, Project Management and Innovation. She led projects of leading brands in Brazil, Argentina and Mexico; coordinated projects of different types of packaging and worked in the development of innovation projects for graphic finishing for paper and paperboard packaging. She is co-author of books of the Better packaging. Better world Collection. For the last five years, she has been coordinating packaging courses, workshops and technical books and teaching classes, at the Instituto de Embalagens. Currently, Simone is a senior consultant at Instituto de Embalagens (Packaging Institute) and FuturePack.

MARGARET HAYASAKI

JOURNALIST

Bachelor of Arts in Journalism from the Universidade Estadual Paulista Júlio de Mesquita Filho (UNESP-Bauru), with a post-graduate degree in Business Communications from the Fundação Cásper Líbero. She has been involved in journalism related to packaging for 25 years. She worked at the editorial staff of the Embanews Magazine and is now the editor-in-chief of Pack Magazine and a communications consultant at Instituto de Embalagens.

EDENILSON SANTOS

GRAPHIC PROJECT& PHOTO

He has a specialization in Digital Design from Centro Universitário FIEO (UNIFIEO) and a postgraduate degree in Packaging: Project Management from the Serviço Nacional da Indústria (SENAI). He has also postgraduate degrees in in Marketing, Strategic Management and Value Generation from FIA. He is currently a Marketing and Communications analyst at Instituto de Embalagens.

COAUTORS MEMBERS OF INSTITUTO DE EMBALAGENS

Claudio Marcondes

Bachelor of Science in Material Engineering from the Federal University of São Carlos (UFSCAR). He has post-graduate degrees in Finance Administration from FAAP, Marketing Business Administration from ESPM, Strategic Innovation Management from Unicamp, and Packaging from the Michigan State University. He has more than 30 years of experience in the areas of product and nanotechnology market development. Currently, he is a Master’s student in Materials Engineering at Unicamp and consultant in nanotechnology. He is a teacher at Instituto de Embalagens and coordinator of the Materials area.

OLINDA MIRANDA

Bachelor in Chemical Engineer from the Faculdade de Engenharia Industrial (FEI), postgraduate in Marketing and Communication, MBA - Alcan Inc and several specialization courses in the technical areas, corporate leadership, people management, finance, and foreign trade. 35 years of experience in flexible packaging, working in the areas of Product Development, Quality, Technical Assistance, Commercial, Marketing, Industrial and Supplies. She worked at companies such as Toga-Alcan-Bemis (now Amcor), Inapel, Empax, CBS Elos. She provided consultancy to the companies Embalagens Diadema, Cepalgo, Jaraguá, Finepack. She currently is a Consultant in the Technical, Commercial and Management areas and a Teacher of Instituto de Embalagens.

INVITED COAUTORS

Adriano Godoi

Graduated in Graphic Designer from Senai - Theobaldo de Nigris and with courses in sales and neo linguistics. Specialist in prepress, graphic arts and flexible packaging, he has been working in the flexographic market since 1995, in addition to being a technical consultant in this segment.

André Garcia Fagundes Badaró

Chemical Engineer with master degree in Business Strategy (stricto sensu), sponsored by Vanderbilt University (USA) also holds a degree in Finance and Marketing from FIA and Fundação Dom Cabral. 12 years of experience in the Petrochemical industry, having worked in the Financial, Marketing and Commercial areas and now leads the Innovation and Market Development team for Paper Packaging at Klabin, within the

Packaging Business.

Célia Freitas

Bachelor of Science in Physics from PUC-SP and postgraduate in Marketing Management from FAAP. She has been working for more than 30 years in the Terphane group. She started her career at Rhodia Têxtil at the Polymer Technology Center. She actively participated in the development of flexible packaging in Brazil, such as stand-up pouch packaging for tomato sauces and cleaning products. She is currently Market Development Manager at Terphane and works in the Brazilian and Export markets.

Elcio de Sousa

Graphic arts technician, with a bachelor’s degree in Chemistry from the University of Guarulhos, and post-graduate in Production Management from the Federal University of Santa Catarina. He specialized in Graphic Production at the Training Center for Graphic Arts in Chemnitz, in Germany, and holds a master’s degree in Mechanical Engineering, Materials and Manufacturing Processes from the University of Campinas (Unicamp). Director of SENAI Barueri School and SENAI Theobaldo De Nigris School. Teacher and consultant for several companies in the graphic arts and packaging areas; professor at the postgraduate course in Packaging Engineering at Mauá Technology Institute. He has worked in companies such as Editora Abril and Van Leer Embalagens Industriais and is a member of ISO’s international standards committee for the graphic segment.

Felipe Toledo

CEO of Camargo Embalagens, graduated in Business Administration, with a postgraduate degree in Business Management and Financial Management from FGV-RJ and OHIO University, and specialization in Family Business Management from IESE-Barcelona. Member of the Board of ABRE – Brazilian Packaging Association and of Dscoop Americas.

Fernando Ferreira

Graduated in Environmental Technology from Mário Amato SENAI Technology Institute and Chemical Engineering from São Bernardo College, post-graduated in Business Management at ESPM, specializing in Environmental Engineering from the University of Campinas (Unicamp). He has 23 years of experience in the chemical industry, in the areas of Quality and Regulatory, R&D and Innovation Processes, mainly in nitrocellulose and polyurethane resins for printing in liquid systems for flexible packaging for the nail polishers, leather, automotive refinishing, and wood segments.

Glaucia Boner de Oliveira

Packaging professional for over 30 years, she is a designer graduated in Visual Communication from the Armando Álvares Penteado School (FAAP) and post-graduated in Applied Consumer Sciences from Escola Superior de Propaganda e Marketing (ESPM). She also took part in the Fundamentals of Packaging course at Michigan State University School of Packaging. She conducts courses, workshops, and lectures on Packaging Design and visits fairs and international events of the sector, such as Interpak (Germany), Metpack Expo (Germany), Fispal, and Brasilpack. She worked in design agencies in Brazil, developing packaging projects for Nestlé, Tintas Coral, Cervejaria Schincariol, Grupo Pão de Açúcar, Cervejaria Antarctica, Sucos Del Valle, Kimberly Clark, Polenghi, among others. Winner of the Best Packaging Award, in the packaging for small and medium enterprises category, granted by the Brazilian Packaging Association (ABRE).

She is the managing partner of Ideia Viva Inteligência Estratégica e Comunicação, and teacher at Instituto de Embalagens.

Guilherme David Benetti

Graduated in materials engineering, specialized in metallurgy, from UFSCar since 2010. He has been working in the aluminum industry for 12 years, where he has worked in primary aluminum manufacturing processes, casting, heat treatments, extrusion of aluminum profiles and, since 2015, working in the area of lamination process for aluminum sheets and plates. Process engineer at CBA.

Leandro Vieira

Engineer specialized in bagging systems, graduated in Mechanical Engineering from UNIMEP - Universidade Metodista de Piracicaba, in 2016. With 14 years of experience in the bagging market, participating in projects to develop new technologies together with Haver & Boecker Germany as well as nationalization processes of equipment to meet the needs of the local market.

Specialist Engineer responsible for determining which technologies will be used in the projects, as well as analyzing the cost-benefit of each project with the client; Layout engineering team coordinator; Head in the implementation of 3D project integration using the Autodesk package between headquarters in Germany and Brazil; Head of a global research and development project involving group companies in Germany, China, India, USA and Brazil.

Levi Vieira de Sousa

Bachelor of Science in Chemistry from Universidade Camilo Castelo Branco, with a Lato Sensu postgraduate degree in Chemistry from Faculdade Oswaldo Cruz and an MBA in Strategic People Management from Faculdade de São Caetano do Sul. Currently working as Coordinator of the technical support team for Nitro’s global customers, in the Chemical Specialties division.

Lucas de Lima Accorsi

Bachelor of Science in Chemical Engineering from UFRGS. Currently working in the aluminum industry for 9 years, have already worked in the areas of electrostatic painting and anodizing of aluminum profiles, coating of aluminum sheets for application in flexible packaging, production in the area of cutting and packaging of aluminum sheets and in the lamination process and aluminum foil cutting. Currently is Process coordinator at CBA.

Mariana Vendiciano Vasconcelos Moura

Graduated in Production Engineering, with a postgraduate degree in Quality and Productivity. 14 years of experience in the Quality area in the industrial sector, of which 12 years are in the aluminum metallurgical industry. Currently is Production engineer at CBA.

Matheus Henrique Seabra Rosa

Bachelor of Science in Chemical Engineer from USP with a specialization in plastics and rubber processing from UFRJ and a postgraduate degree in leadership and innovation from FGV. Holds the current role of R&D manager at Valgroup in the industrial films segment and has eight years of experience in research and development of shrink and stretch films.

RALPH PEREIRA VIEIRA

Bachelor of Arts in Advertising and Marketing from UNIP and technician in precision mechanics from Senai Suiço-Brasileiro. Over 20 years of experience in the technical and commercial areas of packaging equipment, business development and custom packaging solutions for the food, chemical, cosmetics and consumer goods industries. Worked for the companies Mahle, Newell Rubbermaid, Andorinha and Masipack. Has working at Multivac for the last 8 years and currently is its commercial manager.

INDEX

unit | 1

INTRODUCTION TO THE FLEXIBLE PACKAGING UNIVERSE

1.1 Flexible Packaging Market 30

Margaret Hayasaki

1.2 Consumption Trends that Impact in Packaging 36

Assunta Napolitano Camilo

1.3 Innovation 82

Assunta Napolitano Camilo

1.4 Packaging Design 110

Glaucia Boner

1.5 Flexible Packaging Project 116

Simone Ruiz

1.6 Business Model: Digital Printing 125

Felipe Toledo

unit | 2

MATERIALS AND INPUTS

2.1 Polymers 132

Claudio Marcondes

2.2 Polyethylene (Pe): Properties and Applications 133

Claudio Marcondes

2.3 Polypropylene (Pp): Properties and Applications 138

Claudio Marcondes

2.4 Polyester: Properties and Applications 142

Célia Freitas

2.5 Other Polymers 147

Claudio Marcondes

2.6 Masterbatches 156

Claudio Marcondes

2.7 Papers and its Packaging 163

André Badaró

2.8 Aluminum: Properties and Applications 171

Guilherme Benetti

Lucas Accorsi

Mariana Moura

2.9 Inks Resins 179

Fernando Ferreira

Levi Vieira de Sousa

2.10 Inks, Varnishes and Adhesives 183

Olinda Miranda

unit | 3

PACKAGING AND ACCESSORIES

3.1 Films for Flexible Packaging 190

Claudio Marcondes

3.2 Structures and Applications of Flexible Packaging 201

Simone Ruiz

3.3 Types of Flexible Packaging 229

Simone Ruiz

3.4 Labels 249

Simone Ruiz

3.5 Closures, Seals and Accessories 265

Simone Ruiz

3.6 Shrink and Stretch Films 274

Matheus Rosa

3.7 Transport Packaging 279

Simone Ruiz

unit | 4

PROCESSES

4.1 Colors 288

Elcio Sousa

4.2 Prepress Systems 295

Elcio Sousa

4.3 Details of the flexographic prepress system 301

Adriano Godoi

4.4 Printing Processes 305

Elcio Sousa

4.4.1 Gravure

4.4.2 Offset

4.4.3 Digital

4.4.4 Flexography

4.5 Color Standard Control 316

Simone Ruiz

4.6 Metalization and Lamination Processes 321

Claudio Marcondes

4.7 Flexible Packaging Tests 347

Simone Ruiz

unit | 5

MACHINES

5.1 Packaging Systems For Bulk Material 365

Leandro Vieira

5.2 Filling Machines for Liquid and Pasty Products 375

Olinda Miranda

5.3 Atmosphere (Map) Packaging Machines 381

Ralph Vieira

5.4 Labelers 384

P.E. Labellers

5.5 Marking and Coding Machines 389

Olinda Miranda

unit | 6

PACKAGING AND SUSTAINABILITY

6.1 Flexible Packaging & Sustainability 397

Assunta Napolitano Camilo

6.2 Life Cycle Assessment 402

Claudio Marcondes

6.3 Environmental Certifications, Simbology and Labeling 409

Assunta Napolitano Camilo

6.4 Circular Economy 429

Assunta Napolitano Camilo

6.5 Environmental Friendly Packaging and Projects 445

Assunta Napolitano Camilo

Bibliographic references and credits 463

SponsorS 484

Flexible Packaging Market

Margaret Hayasaki

The global demand for flexible packaging (paper, aluminum foil and plastics) must grow at a compound annual growth rate (CAGR) of 3,2% totalizing a global value of Us$ 294,1 billion in 2026. In the same period, total flexible packaging volume will increase from 32,33 million tons to 39,54 million tons.

The Asia-Pacific region will be responsible for the biggest growth, with a CAGR of 5,4% in the next five years (2021-2026). The decrease will be slowest at Occident Europe, followed by Latin and North America. The Occident Europe market is widely saturated and the expectation is to reach an average annual growth of 1,9%. Besides that, the region also suffers an increasing pressure to substitute hard recycling plastic in many important applications. The European Union Single Use Plastics Directive, that forbids single use plastics, including oxybiodegradable plastics, came into force in July of 2021.

Other plastic restrictions are at Europe sight for the next decade. In some applications, the substitution for a new generation of paper flexible packaging is turning specially attracting in function of brands perception and to be in conformity with the legislation. This is already stimulating paper packaging evolution, and in particular, structures that can offer proper barrier protection.

Photo: Miska Sage on Unsplash

The green-alternatives in development inside plastics include:

Using more recycled plastic without committing to the materials performance;

Improving the recyclability of the current packaging with monomaterial structures;

Identifying proper markets to flexible biopolymers.

The Brazilian flexible plastic packaging industry registered gross revenue of R$ 43,6 billion in 2021, a variation of more than 55% comparing to 2020. The good performance of the sector is attributed mostly to the increase of the prices in all the productive channel, from the raw material to transformed products, according to a Maxiquim study done to ABIEF (Brazilian Association of Flexible Plastic Packaging Industry).

Brazilian flexible exportation grew in volume, with a commercial balance of over 51 thousand tons, and also in value, contributing exportations participation at the total of plastic transformed was 18% in 2021 relating to 2020, while importations grew 15% in the same period.

Final Use Applications

Photo: Laura James on Pexels

Food segment still the biggest application of final use to flexible packaging, being responsible for 75,5% of total volume of use in 2021. Covid-19 pandemic had a large impact in diverse areas, including economy, productivity and, at demand in final use sectors; and suppliers and brand owner priorities.

Flexible packaging pack more than 50% of food on Europe, using only 17% of all consume of packaging material, according to Flexible Packaging Europe (FPE). The market-share, by application, stablished leadership of the following categories: pet food, biggest shelf-life food, coffee, and snacks. Flexibles growth at coffee segment is attributed to home consumption.

Photo: Pulsitos.com on Unsplash

Food industry is also the main market to flexible plastic packaging in Brazil. In 2021, the segment responded for 896 thousand tons of 2,1 million tons produced, equivalent to an increase of 8,4% comparing to 2020. Packed food sales are stronger than other goods in economic downturn periods. Covid-19 pandemic changed consumer behavior that began to make meals at home – and will continue to support this change. Fast expansion final use markets include meat, fish, poultry and frozen food, with global annual average growth rate of 5,9%.

An emergent tendency at post-Covid world is the use of refill type of packaging to self-care and domestic products. This gave rise to a new potential to refill sort of plastic packaging that reduce environment