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PAC Award Winner-Bronze

Boehmer Box's package for Concord Premium Meats Ltd - Sleeve for MarcAngelo TM

Overview

Boehmer Box LP, a leading Canadian folding carton manufacturer, worked with Concord Premium Meats Ltd to re-launch its new branded packaging using a greater level of sustainable packaging as well as environmentally friendly materials and processes.

Through Boehmer Box’s “Eco Adaptation” program for environmentally conscientious packaging, the carton design, graphical reproduction, materials of construction and product packaging were all evaluated to highlight areas within the project where the environmental impact could be minimized and to enhance the environmental sustainability of their packaging.

For this project the packaging was produced in an environmentally progressive manner due to two major factors – 100% recycled GreenChoice 100 paperboard and FM6 ecologically friendly print process.

For the packaging substrate, Boehmer Box used GreenChoice 100, Strathcona Paper’s 100% recycled clay coated boxboard, which is a unique eco-friendly packaging substrate. In addition to having Eco Choice certification, Strathcona Paper’s GreenChoice 100 is made from 100% recycled fibers, is 100% recyclable and is the first and only recycled paperboard that is 100% carbon neutral and 100% of the energy used in its manufacture is offset with clean renewable energy. As a result, Concord Premium Meats Ltd. is able to print on each of their cartons, in addition to the Eco Choice logo, a GreenChoice 100 logo designed to communicate in an impactful and easy to understand manner for consumers that demonstrate the brand and Concord Premium Meats Ltd commitment to eco responsible packaging.

Additionally, the superior strength properties of Strathcona Paper’s GreenChoice 100 paperboard also makes it an ideal substrate for reducing caliper, using less packaging substrate, and saving money.

For the printing of the package, Boehmer Box used FM6, a patented printing process technology which is far more environmentally friendly and sustainable than conventional offset printing processes. Due to FM6’s ability to print to density consistently, the print process has the following significant sustainable advantages:

• It uses fewer sheets in the make-ready process;

• It uses less inks than conventional offset printing;

• It eliminates some printing press make-readies and press wash-ups and therefore the consumables associated such as printing plates, paperboard, energy and wash up chemicals;

• Less volatile organic compounds (VOC’s) are emitted into the atmosphere using FM6 compared to conventional off-set lithographic printing.

Concord Premium Meats Ltd was able to combine multiple eight color jobs on one press run on a 10-up die. This offers increased flexibility to combine multiple sku’s on one make ready and to optimize the order quantity of each stock keeping unit. This reduces cost by combining numerous smaller runs into a single, higher volume run; with lower carton inventory and storage costs across all product ranges.

For this project we validated that the caliper of the paperboard was already optimized but there was an opportunity to right size the sleeve and save the amount of paperboard required for each sleeve. Through the use of a software program for pallet optimization, we also were able to maximize the quantity of cartons per pallet and therefore achieved energy saving by reducing pallet moves.

In addition, all light bulbs in Boehmer Box’s manufacturing facility have been replaced with lower energy light bulbs and motion detector controlled lighting is utilized to minimize the duration that lights are left on. Boehmer Box’s sales office in Toronto is powered with clean green energy.

All cleaning materials and scrap from the converting process are sent for recycling, thereby ensuring the packaging’s continued sustainability in the future.

Motivation for Change

Concord Premium Meats Ltd was looking to freshen and rejuvenate the look of this sleeve and to create a higher level of environmental sustainability for their brand image. The objective was to highlight their traditional family core values including excellence in quality and taste and the environment.

Boehmer Box worked with Concord Premium Meats Ltd within the framework of our “Eco Adaptation” program for environmentally conscientious packaging. This involved the carton design re-evaluation, raw material selection, and graphic reproduction process to enhance the environmental sustainability of their packaging.

Cost Effectiveness

The folding carton substrate is a carbon neutral 100% recycled paperboard. GreenChoice 100 is competitively priced compared to other recycled paperboard substrates, however, more significantly GreenChoice 100’s superior block compression strength and stiffness as measured by the MD(machine direction):CD(cross direction) ratio relative to all other North American recycled boards creates opportunity to reduce caliper of the substrate used in the package without sacrificing performance on the filling line or in the retail arena.

This superior stiffness allows a folding carton converter to reduce the caliper of the packaging substrate and “right size” packaging using less board and thereby saving both money and materials. In addition, GreenChoice 100’s printability is second to none with higher brightness and plybond than industry averages providing strong graphic reproduction, which together with its strength properties allow increased press efficiencies.

FM6 is a patented printing process technology that prints the image and spot colors to a predefined density. This allows the reproduction of the traditional Pantone spot color library in a single printing pass utilizing CMYK and the special colors of FM orange, FM blue, and FM green. However this process requires certification through rigorous process standardization to effectively operate. This includes:

• Rigorous quality controls to minimize variability of the paperboard, press blankets, inks and press maintenance.

• Printing Press Profiling (Fingerprinting)

• Proofing system profiling / alignment (icc)

• Computer to plate proprietary compensation curves

• Electronic data file to press with preset conditions for press conditions and ink key settings.

These processes create exceptional color control, consistency, stability and minimize the risk of print related defects. These qualities, together with less ink and chemical usage, plus the savings from having fewer make-readies, less energy consumption, less man-hours and less paperboard, means that cost savings can be realized. In addition, less volatile organic compounds (VOC’s) are emitted into the atmosphere using FM6 compared to conventional off-set lithographic printing.

Performance

The consistent high color and enhanced images on the packaging obtained by using the FM6 print process increases shelf and retail presence. Concord Premium Meats Ltd was able to combine multiple eight color jobs on one press run on a 10-up die. This offers increased flexibility to combine multiple sku’s on one make ready and to optimize the order quantity of each stock keeping unit. This reduces cost by combining numerous smaller runs into a single, higher volume run; with lower carton inventory and storage costs across all product ranges.

Additionally, GreenChoice 100’s proprietary fiber recipes run at one of the lowest conversion rates of fiber to finished paperboard in the industry reducing the amount of waste that would otherwise need to be diverted to landfill.There are absolutely no performance trade-offs as a result of implementing more sustainable materials and processes.

Sourcing

Strathcona Paper’s GreenChoice 100 paperboard is manufactured from 100% post-use recycled waste paper fibers. Approximately 65% of this post-use waste is post-consumer material and 35% is industrial scrap. For this sleeve, the GreenChoice 100 was produced with an application of special biodegradable sizing agent to provide moisture resistance to the paperboard.

GreenChoice 100 is manufactured by Strathcona Paper LP, the only 100% recycled clay coated boxboard mill in North America to have its Environmental Management System registered to the rigorous global standards of ISO 14001, having achieved this status since 2001. In addition, in 2007 Strathcona Paper received Environment Canada’s Environmental Choice Certification, EcoLogoM, and again, is the only North American recycled paperboard mill to achieve this standard.

Strathcona Paper, as recycled paperboard manufacturing specialists, has always felt it important to exceed these standards whether in its manufacturing and supply chain processes or in its products and it was with this philosophy that the idea of GreenChoice 100 was conceived. Clean and sustainable GreenChoice 100 while all carbon emissions are offset through tree planting and watershed soil protection programs.

Effective Recovery

The packaging substrate is 100% recycled, recyclable and carbon neutral and is made from 100% recycled waste paper fiber acquired from compatible recovery infrastructures throughout North America using a closed loop cradle to cradle recycling system. The folding carton itself is recyclable through these same recovery infrastructures. In addition, as part of the closed loop system, all waste clippings produced in the folding carton manufacturing process are returned to the Strathcona Paper mill as a recycled fiber source.The folding carton was designed to ensure no materials were used that would minimize the opportunity to recycle the carton including the use of cellophane windows or wax coating.

The paper sludge biosolids generated in the manufacture of all of Strathcona Paper’s products including GreenChoice 100 are composted and spread on local farmers’ fields as a soil conditioning agent improving water retention and the organic content in the soil and reducing the amount of commercial fertilizer that the farmer would otherwise have to use. The composted biosolids also add micro nutrients such as copper and zinc which are important to crop production. All cleaning materials, printing plates and other waste incurred in the converting process are sent for recycling or reclamation.

Community Benefit

The use of GreenChoice 100 and the more environmentally friendly FM6 printing process provides a clear environmental choice for Concord Premium Meats Ltd to have its packaging made with the best sustainable paperboard packaging substrate and converting technology. This packaging using the above sustainable materials and processes allows Concord Premium Meats Ltd to answer a market need to differentiate their packaging and provide their consumers with a more environmentally sustainable impact of their consumption choices.

The use of GreenChoice 100 as the paperboard substrate in a folding carton allows Concord Premium Meats Ltd to use a number of eco-certified logos, of which they used the TerraChoice EcoLogo and the GreenChoice 100 logo on their packaging. The EcoLogo certifies and informs consumers that any product bearing this logo meets or exceeds a complete environmental lifecycle audit analysis, from energy and material consumed in production through to pollutants generated by their production, use and disposal. In using these eco-certified logos, Concord Premium Meats Ltd has the opportunity to educate and demonstrate their level of eco responsibility and sustainability at shelf directly to the consumer.

Material Health

All existing and new chemicals proposed for use at Boehmer Box and Strathcona Paper are evaluated for both the human health and safety and environmental impact of the chemical. This selection process ensures both of these areas will receive minimal impact while meeting the needs of the end use product.

The packaging substrate, GreenChoice 100, is in compliance for direct food contact under the regulatory frameworks of the US Federal Food and Drug Administration Act (FDA) and the California EPA Proposition 65. The Canadian Food Inspection Agency has issued a letter of non-objection for direct food contact for GreenChoice 100. Strathcona Paper was the first 100% recycled boxboard mill to receive this letter of non objection for direct food contact.

Less VOCs are emitted through the use of FM6 printing technology in addition to the inks, coating and chemicals themselves being environmentally responsible.

The Concord Premium Meats Ltd branded package is not only 100% recycled and recyclable, and carbon neutral, but is also biodegradable and compostable in an actively managed composting facility. No toxic chemicals are used in the production of GreenChoice 100. ISO 14001 and Environmental Choice certification also reflect environmentally safe and end of life scenarios for the packaging substrate.

Resource & Energy Optimization

As noted above, GreenChoice 100 is made from 100% recycled materials. All the electricity consumed in the production of GreenChoice 100 is offset through the purchase of renewable energy credits. Strathcona’s mill has also reduced the energy consumed per ton of paperboard produced by 13% over the period 2004 to 2008, and reduced carbon dioxide emissions by 13% from 2004 to 2008. Both results showed a continuing improvement over the results achieved from 2004 to 2007.

All carbon emissions produced in the manufacture of GreenChoice 100 are offset with the purchase of carbon credits.

Water used in the paperboard manufacturing process is cleaned and returned to the natural water source in a 100% closed loop recycling process. 85% of the water used in the paperboard manufacturing process is recycled, the balance is emitted in the form of steam.

Printing using FM6 technology uses less plate sets to achieve multiple colors reducing the number of print runs, saving on materials and recycling. This reduction in make readies in printing and therefore die cutting, resulting in savings in energy consumption, paperboard, ink and chemicals. In addition, less volatile organic compounds (VOC’s) are emitted into the atmosphere using FM6 compared to conventional off-set lithographic printing.

Paperboard trim waste produced in the converting of Concord Premium Meats Ltd branded folding cartons produced at Boehmer Box is sold back to Strathcona Paper mill for recycling and is backhauled by Strathcona Paper’s transport fleet reducing the transportation involved if it was brokered out to the market.

Categories: Food and Beverage PAC Award Winner Retail

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