DAILY NEWS

Introduction

Since the paradigm shift in 2015, the industry has been striving toward a Circular Economy. The packaging industry also is moving in the same direction and moving in the direction of circular packaging. New attempts are being made while trying to respond to the SDGs. Now flexible packaging is at a turning point. At the stage of packaging design, in addition to the current consideration of functionality such as content protection and usability, it has become necessary to consider the recovery and reusability of used packaging materials. The concept of circular polymers, recycling-oriented polymer utilization, is ahead of the curve, and it is still difficult to judge what kind of recycling technology is appropriate, now we have no choice but to move forward.

1．Use of non-petroleum materials

In terms of preventing global warming and conserving global resources, many efforts are being made to save plastic materials and manufacturing energy, and collect used plastics for reuse as raw materials.

• 1.1 Lightweight and strong films
• 1.1.1 OPP with stiffness and rigidityToyobo has developed an ultra-high-rigidity OPP film, “PYLEN® EXTOP TM,” which has about 1.7 times as strong as the stiffness of general OPP film and can be 20% thinner. Anti-fog type, high heat-resistance type, etc. are scheduled to be on sale from the fall of 2022. It can reduce the amount of plastic and carbon dioxide emissions during combustion.
  https://www.toyobo.co.jp/news/2022/release_1353.html
  Toray has developed a heat-resistant OPP film. Since it can be used in a high-temperature environment of 120°C, it is possible to develop it for boiling pouches and low-temperature retort applications.
  https://www.toray.co.jp/news/details/20210317001590.html
• 1.1.2 Biaxially oriented PBT filmKohjin Film & Chemicals can supply biaxially oriented PBT film produced by the tubular method. It has excellent pinhole-resistance (especially excellent resistance to bending fatigue and wear), equivalent suitability for producing laminate-films and acid resistance as PET. There is no dimensional change due to moisture absorption, and since it has the features of both PET and ONY, it is possible to simplify and reduce the weight of the packaging material.
  https://www.kohjin.co.jp/product/film/convert/boblet/
• 1.2 Use of Bio-based FilmsThe use of Bio-PE and Bio-PP derived from sugarcane pomace and woods is gradually increasing. The trend of a slight increase continues. These will also be collected and used as raw materials.
• 1.3 Change from films to papers
• 1.3.1 Ajinomoto Frozen Foods uses paper for part of the packaging of home-use frozen food “Jidori Kamameshi”The Ajinomoto Group has released the first packed frozen food that partially uses paper in Japan.
  • (a) expect to reduce the amount of plastic by about 9.7% compared to conventional products.
  • (b) The bamboo skin motif package design can be felt by the touch because of the use of paper. It also succeeded in further strengthening the product concept of“specialty store-quality Japanese rice”.
  • (c) The corporate mascot “Aji Pen ECO” mark is displayed on the back of the package in order to inform consumers at a glance that the amount of plastic used has been reduced.
• 1.3.2 Adoption of paper for secondary packageEven if the secondary package is not film, there is a strong movement to switch to paper if the purpose can be sufficiently achieved with paper. (photo1)
• 1.4 Use of bio-based inks and adhesivesFrom the perspective of moving away from petroleum, inks and adhesives derived from bio-based materials have been developed, and their use is gradually increasing.

2. Preliminary step towards circular packaging

Technological development to effectively use mechanically recycled products is progressing.

• 2.1 Support technology for mechanical recyclingProfessor Yao of Fukuoka University has developed a technology to prevent deterioration of the physical properties of plastics, and it is underway toward practical application. Hitachi has developed a system that can modify the conditions during injection molding even if the physical properties of the recovered plastic vary slightly.
• 2.2 Use of bio-naphthaMitsui Chemicals is the first company in Japan to use Neste’s biomass naphtha to manufacture bio-PP and other plastics and chemicals using a mass balance method based on ISCC PLUS certification.
  https://jp.mitsuichemicals.com/jp/release/2021/2021_1214.htm

3.Toward the construction of utilization of circular polymers

Plastic packaging materials are basically collected after use and reused as raw materials for manufacturing new plastics. The time will come when the use of recyclable plastics will become a matter of course.

• 3.1 Toward a demonstration experiment of chemical recyclingChemical recycling has been in operation for more than 20 years since the Containers and Packaging Recycling Law was implemented, but now attention is focused on methods for remanufacturing plastics. Flexible packaging is laminated with films, aluminum foils, and papers, and it is not yet clear which chemical recycling method is suitable for which packaging specification. It will become clearer by repeating demonstration experiments in the future.
• A) Pyrolysis oil typeThere is a movement to save petroleum-derived naphtha by using pyrolysis oil, and the concept of mass balance method is used for manufacturing. The domestic market is in the preparation stage.
• B) Gasification typeSekisui Chemical has completed a pilot plant in KUJI City, and it is expected that the technology will be put into practical use to produce ethanol by using LanzaTech’s technology to convert CO gas generated by burning household waste, waste plastics, and wood waste into plastics.
• C) Supercritical typeMitsubishi Chemical has introduced Mura Technology’s technology based on Licella’s technology and is preparing for demonstration tests for practical application.
• D) Delamination type by SolventThere is a movement of deinking from waste packaging materials generated in the manufacturing process of converters and reusing them as raw materials for films.
  https://jp.mitsuichemicals.com/sites/default/files/media/document/2019/191115_0.pdf
• 3.2 Regarding the collection of plastic packaging based on the Containers and Packaging Recycling Law.Based on the Containers and Packaging Recycling Law, plastic containers and packages are collected, but if there is food or other body residue attached to it, these are contained in household waste, and the amount discharged as household waste is unexpectedly large due to research by The Japan Containers and Packaging Recycling Association. They act a role of combustion improver for household waste. We would like to devise ways to use plastics mixed in with household waste for the production of circular polymers.
• 3.3 The collection of plastic resources based on the recycling promotion lawThe law was implemented on April 1st, 2022. 12 items will be collected, but the collection method will be decided by the local government. It is expected that waste plastic will be collected as much as possible using the recycling method based on new law.
• 3.4 Regarding the safety of recycled plasticsCollected plastic containers and packages are disposed of from the household based on the recycling law. The collection based on the plastic resource recycling promotion law is also from the household, and it can be judged that its safety is guaranteed. Other than these waste plastics, it is important to check the source of the discharge and track it.

4. Small run production

People’s tastes and needs have become diverse, and the demand for uniform products has decreased, the life of products has become shorter, and the production volume of products has become smaller than before. In packages production process, Gravure printing is close to its limit because of the lack of profit and lack of operators. Instead of gravure printing, inkjet digital printing is starting to become popular, and applied products are also increasing. After the printing process, non-solvent lamination and new lamination methods are used, and the production system changes.

5. Functional packages

Functionality is important to packaging, and its features have changed with the times. Recently, there has been a movement to provide various information and entertainment to consumers by reading the QR code on the surface of the packaging with their smartphones. It’s called as connected package and it’s becoming more popular overseas. Also, easy open packaging is an important theme. A New package using a laser cut technology was developed, and the cut part is left in the package after opening. The cut part is not scattered, so it is possible to prevent marine plastic pollution. (Photo 2)

6. AI, IoT, Robot

The most advanced technologies such as AI, IoT, and robots are applied widely in the packaging industry due to a packaging shortage of human resources and a lack of skilled workers.

• 6.1 AI
  ・In the case of the packaging of scallop, skilled workers judge the weight of the body by the feeling of touch, and pack it quickly.　New workers cannot pack quickly such as skilled workers. It takes many times to train new workers and is difficult to inherit the technology.
  In order to the solve the problem, AI solutions for mass estimation, AI Selector is used.
  https://monoist.itmedia.co.jp/mn/articles/2202/16/news045.html
  ・Introduction of AI in package graphic design. AI evaluates product package graphic design in 10 seconds. In addition to shortening the product development period, we can get hints for graphic design improvement.
  https://hp.package-ai.jp/
• 6.2 Robot The UK Recycleye company’s system is noted. It is a combination of Recycleye Vision’s image processing technology and FANUC’s Recycleye Robotics. It is operating in England, Italy, Germany, and France.

Summary

Flexible packaging acts its role by applying full use of changes or new products and new technologies in response to the changing times. From the standpoint of reducing CO2 emissions, the packaging industry is moving in the direction of reducing the waste of packaging materials. Among them, inkjet digital printing will grow steadily as a technology of the times.

Mitsuhiro Sugimoto，Professional Engineer
SUMIMOTO PACKAGING　CONSULTANT OFFICE