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PAC: Branded Package (made in Canada) - Bronze

UltraTill Mushroom Packaging

Overview

In response to decreasing waste in landfills in the future, and as an alternative to plastics, Cascades developed a 100% recyclable mushroom package made entirely from recycled fibres, principally from old newsprints and phonebooks. The production of the mushroom package helps to divert 1.5 tons of recycled paper per day from being landfilled.

Motivation for Change

As when the Intergovernmental Panel on Climate Change (IPCC) is anticipating increases from 1.8 to 4 degrees Celsius for the next hundred years, in 2006, we generated in Quebec 12,952,000 tons of waste from which 6,717,000 were landfilled. But the gazes issued from the decomposition of waste meant to be landfilled (45% of methane, 35% of carbon dioxide, 15% of nitrogen, 5% of oxygen and some traces of hydrogen and hydrogen sulphide) hold a warming power which contributes to the climate changes.

Facing these observations, and to offer to the environmentally-concerned companies an alternative to plastics, Cascades Forma Pak has developed a 100% recyclable mushroom packaging made entirely from recycled fibres.

Cost Effectiveness

Forma Pakís mushroom packaging was designed to perfectly adapt to our clientsí equipment. In fact, Forma Pak had first made 6 and 8 oz square containers and tested 100 000 of them back in 2006. Economic advantages of moulded pulp containers, in comparison with other containers are especially related to a better conservation of the product to be packed: the mushroom.

Performance

Moulded pulp packaging is made without any wax agent, and slows down the development of bacteria (which cause food rot) by absorbing humidity.

Sourcing

UltraTillís raw materials are 100% recycled fibres, principally from old newsprints and phonebooks. The production of mushroom packaging helps to divert 1.5 ton of recycled paper per day from being landfilled. Moreover defective containers are returned into the process.

Clean Production

Forma Pak realises great achievements in terms of water consumption. Water is used in very small quantities (0.2 m2 /ton, while the Canadian industry average is 52 m2), and circulates in almost closed loops, allowing the plant to reject very small quantities of water. The water used in the process is coming from Nicolet Sud-Ouest River via Cascadesí pumping station, goes through Cascadesí wastewater treatment and returns to the river, clean and almost exempt of suspended solids.

Forma Pak manages the hazardous waste (used oils and solvents, out of date chemicals, etc.) in a very safe way for the employees and the community. A specialized firm then carries the waste to a landfill. Moreover, the amount of waste generated is very small as no harmful chemicals are used in our processes.

Effective Recovery

Forma Pakís mushroom packaging can be recycled or composted. Ending up in a landfill, they would be biodegradable within 2 to 5 months. This product, if well managed, will never end up in a landfill, but will be reintegrated into the recycling process.

Resource & Energy Optimization

The majority of our raw material is found within a 350-kilometer area, which eliminates a great quantity of greenhouse gases (GHG) produced by transportation. As a result that Forma Pak has dropped off its GHG emissions by 2% in 2007. Moreover, Forma Pak uses Cascades\'s paper mills waste as raw material in its moulded pulp production. Some of the usual raw material is therefore being replaced by cellulosic fibres waste fibres, which increases the plantís valorization rate. The waste is mixed with the other raw materials in the pulper. Finally, Cascades has also dropped off its energy consumption by 3.5% since 1990 and uses hydroelectricity (21%) and natural gas (79%).

Categories: PAC Award Winner Paper & Board Food and Beverage

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