Consumer packaged goods (CPG) companies are under pressure to create more sustainable packaging. Now, faced with the inevitable move to environmentally friendly products, manufacturers are reassessing the materials, the packaging machines, and the recycling responsibility. All of which starts with the packaging design.
Dassault Systèmes provides software that can optimize the design process. Packaging OEM asked Raymond Wodar, the company’s global director business consulting for the CPG and retail industry, how the initial design impacts the entire product lifecycle — and how to start the process.
Who in a CPG organization is responsible for sustainable design?
Wodar: In a consumer packaged goods organization, sustainable design is typically a cross-functional effort that involves several departments and roles. The brand marketing function will likely define the parameters for the project and the packaging design and development teams are responsible for incorporating sustainable materials into the design. The teams need to work with internal sustainability or environmental affairs groups that will provide the goals and standards needed to achieve sustainability targets. Supply chain and procurement teams will also be involved for sourcing sustainable materials and managing the logistics packaging requirements. Other functions may involve advanced R&D topics like materials research and help from outside agencies to determine latest trends and consumer requirements.
Beyond materials, what needs to be considered when creating a sustainable package design?
Wodar: When creating a sustainable package design, several factors beyond just the choice of materials need to be considered to minimize environmental impact and enhance overall sustainability. The design should be optimized to minimize the size and weight of the package to decrease material usage and excess packaging while still effectively protecting the product. A lighter product will also reduce transportation emissions in the supply chain. A thorough evaluation of the entire supply chain will help understand the environmental impact from production through to transportation and distribution. This includes considering how far materials and finished products need to travel and the associated carbon footprint of that journey.
Considerations for end-of-product-life are critical as well. This involves designing for disassembly (if applicable), providing clear recycling or disposal instructions, and considering the lifecycle impact of the packaging once it has been discarded. Using materials that are widely accepted by recycling systems or that can biodegrade in industrial composting facilities is critical.
For a brand manufacturer, the cost profile of the package will be very important so that tradeoffs between material cost, weight, and quality can be properly balanced to provide the consumer a great value while managing internal product margins.
What are the regulatory pressures associated with sustainable packaging?
Wodar: Regulatory pressures related to sustainable packaging are increasingly influencing how companies design, produce, and manage packaging. These pressures come from various levels of government and regulatory bodies and can vary by region. Many regions are implementing extended producer responsibility (EPR) programs that require producers to take responsibility for the entire lifecycle of their packaging, including end-of-life disposal and recycling. Companies may need to manage or contribute to the costs of collection, recycling, or disposal. Several countries and states have introduced bans or restrictions on single-use plastics and certain types of packaging. Regulations might limit or prohibit the use of plastic bags, straws, or other single-use plastic items, pushing companies to seek alternative materials or packaging solutions. Governments are starting to set targets for waste reduction, recycling rates, or the reduction of packaging waste. Companies are often required to meet these targets or face penalties. For companies operating globally, international regulations and agreements, such as the European Union’s Packaging and Packaging Waste Directive, can affect packaging design and sustainability practices.
How can 3D modeling software help?
Wodar: 3D modeling software enhances the design process by providing a detailed, interactive platform to explore and optimize sustainable packaging solutions, leading to more effective and efficient design outcomes. 3D modeling software allows designers to create detailed visual representations of packaging designs. This helps in visualizing how sustainable materials and design choices will look and function in the real world before physical prototypes are made. Before creating physical prototypes, 3D models can be used to simulate how the packaging will behave under various conditions. This includes testing durability, functionality, and fit, which helps in optimizing the design for better performance with sustainable materials. More advanced 3D modeling tools can also integrate with lifecycle assessment (LCA) software to evaluate the environmental impact of packaging designs. This helps in understanding the potential environmental footprint of different design choices and materials.
What does a virtual twin do?
Wodar: A virtual twin is not only a digital replica of a physical object, system, or process, but it integrates real time data, simulations, and analytics to provide a comprehensive and dynamic model that mirrors the real-world counterpart. The most powerful part of virtual twins is the ability to perform ‘what-if’ scenario analysis. This allows for simulation of various scenarios and testing of different conditions without impacting the physical entity. Imagine testing how a package will behave when dropped, or when stacked in a pallet, or when going through temperature extremes, without needing to use a physical prototype. This is useful for assessing the impact of design changes, operational adjustments, or environmental factors. More advanced virtual twins can predict future performance or potential issues based on historical data and simulation results.
Can creating a virtual twin using 3D modeling software accelerate the time-to-market for a sustainable package design?
Wodar: Yes, using a virtual twin created with 3D modeling software streamlines and accelerates the entire process of sustainable package design. By enabling rapid design iterations, accurate simulations, and efficient collaboration, it reduces the time required to bring a new sustainable packaging solution to market. Designers can simulate how different design changes impact the packaging functionality, sustainability, and consumer appeal without the need for physical prototypes. This includes testing how the packaging performs in various conditions. This highly compresses the time needed to validate the design. Virtual twins also enable the testing of different sustainable materials to evaluate their performance, recyclability, and environmental impact, leading to better material selection and design optimization.
What are the other benefits of using a virtual twin in sustainable design?
Wodar: Virtual twins offer a wide range of benefits in sustainable design, from cost savings and quality improvements to enhanced collaboration and environmental impact reduction. By leveraging these advantages, organizations can drive innovation, optimize design processes, and achieve their sustainability objectives more effectively. Using virtual twins minimizes the need for physical prototypes, saving costs associated with materials, manufacturing, and testing. By optimizing designs and processes virtually, companies can reduce material waste and energy consumption, leading to lower production costs and a smaller environmental footprint. Virtual twins enable designers to fine-tune every aspect of the design for optimal performance, durability, and sustainability. This leads to higher-quality products that meet or exceed performance expectations.
What is the Dassault Systèmes product that CPGs would use to accomplish this?
Wodar: It is called the Perfect Package industry solution experience. The comprehensive solution helps CPG companies design and optimize packaging in record time. Capabilities include structural design, modeling and simulation (MODSIM), project management, specifications management, lifecycle analysis, and more.
Is understanding the production of the sustainable package part of the process?
Wodar: Yes, understanding the production of a sustainable package is integral to ensuring that the packaging is truly sustainable. It helps in making informed decisions about materials, manufacturing processes, and cost implications, ultimately leading to a more effective and environmentally responsible packaging solution. Different materials may require specific manufacturing processes. Understanding these processes helps ensure that the packaging can be produced efficiently and sustainably. For instance, some materials may need specialized machinery or processes that could impact production costs and the environmental profile. Also, assessing the energy consumption, water use, and waste generated during production is vital for understanding the overall environmental impact. Sustainable production practices aim to minimize these factors.
What is the responsibility of the machine builder in this sustainability journey?
Wodar: The machine builder’s role is integral to the sustainable packaging journey. Their involvement in designing, producing, and supporting efficient and adaptable machinery helps ensure that packaging manufacturers can meet their sustainability goals effectively. By collaborating with other stakeholders and focusing on energy efficiency, material compatibility, and innovation, machine builders contribute significantly to the advancement of sustainable packaging solutions. Builders must ensure that their machinery can handle and process sustainable materials, such as biodegradable films, recycled paper, or alternative substrates, without compromising performance or quality.
In a circular economy, does recycling of the package come into the design process?
Wodar: Yes, in a circular economy, the design process is significantly influenced by how the package will be recycled. The principles of a circular economy aim to minimize waste and make the most of resources. This requires considering the entire lifecycle of a product, including its end-of-life stage. Key considerations in the design process for packaging in a circular economy include choosing materials that are recyclable and can be separated easily from other components. Biodegradable or compostable materials might also be considered.
