After more than 18 months of research and design, San Diego-based Bear Naked granola brand by Kellogg's, a food manufacturing company headquartered in Battle Creek, Michigan, is now the first fully recyclable stand-up pouch on the market nationwide.   The recyclable pouch made with a food-grade packaging barrier means that consumers can recycle their granola bar bags at about 18,000 retail stores across the nation that collect plastic bags and other types of plastics for recycling.   For the past 10 years, Kellogg has partnered with Trenton, New Jersey-based TerraCycle to recycle its multilayer packaging through the company’s mail-in program. The brand recycled more than a half-million pouches through the program. For Kellogg to recycle its packaging through the store drop-off program, and reach more consumers, the brand had to design a recyclable film. Working with Dow, Midland, Michigan, Berry Global, Evansville, Indiana, and several other packaging suppliers, Kellogg developed a new a monolayer polyethylene (PE) pouch, says Shannon Moore, Kellogg’s lead packaging engineer.   “When the brand had decided they wanted to go a bit further with their sustainability story, we spent some time working with our existing packaging suppliers and film converters,” Moore says. “The common denominator for all those converters was they were getting their postconsumer resin (PCR) from Dow.   “We met at their facility and we started working with some of their partners who also supplied Kellogg. We all worked together to figure out how to create a package that looked exactly like what was on the shelf and had the same look and brand feel.”   Kellogg makes the PE pouch using Dow’s Retain polymer modifier technology, which allows converters to combine other PE resins to fabricate recycled films without sacrificing physical or optical properties. The PE films made with Retain are approved for the How2Recycle logo by the Sustainable Packaging Coalition (SPC), according to Dow.   “I’m really excited about this technology and I’m sure other consumer goods companies are going to start similar projects,” Moore says. “The technology allows for a higher barrier material to go through the store drop-off process and to be used by Trex and other end markets. That’s really important.”   Making sure the material, including the recyclable zipper developed by Fresh-Lock, was compatible with Kellogg’s existing bagging equipment was a big challenge in the development process, Moore says.   “PE has a much lower melt temperature than a traditional multilayer pouch, so working around the film properties for that was a challenge,” she says. “The bag itself has a window, so maintaining clarity of the window that we had previously was a challenge. Then on top of that, we have a matte finish, so we had to do several trials to get that printing process correct.”   Regarding Fresh-Lock’s recyclable zipper, Moore says, “We brought them in to make sure that the zipper didn’t melt through the film while we were sealing it on the bagger. The material they were using had to be fully recyclable, so we had to make sure they were getting the correct certifications to make it fully recyclable with the bag so we didn’t have any challenges when we went to the store drop-off program.”   Kellogg began working on the Bear Naked recyclable pouch when the brand joined United Kingdom-based Ellen MacArthur Foundation’s New Plastics Economy initiative.   “Having the EMF commitment and being a signatory allowed us to come together and start working on sustainability more broadly,” Moore says. “This project is nice because it allows us to start looking at how we can incorporate this technology into other Kellogg brands that use similar packaging formats and what would it take for us to do this in a different brand.”   Currently, there isn’t any recycled material used in the Bear Naked packaging. Moore says there’s more work that needs to be done in developing food-grade PCR. The pouches also aren’t recycled into new pouches, yet, but closing the loop is something Kellogg is trying to figure out, Moore says.   “We’re looking at how can we incorporate food-grade postconsumer resin, so we can have recyclable content in our material,” she says.   Many flexible plastic packages, including plastic bags, can’t be recycled through curbside recycling programs. Last year, Kellogg joined the Film and Flexibles Task Force led by The Recycling Partnership, Falls Church, Virginia. The task force is working to define, pilot and scale recycling solutions for the more than $31 billion dollar packaging industry, including plastic film, bags and pouches, according to the nonprofit.   “We became a partner at the end of last year,” Moore says. “It’s really helped us get more involved in what does the infrastructure look like and what are the challenges that are going on with infrastructure. It’s allowed us to get our hands dirty and work alongside other consumer goods companies that have similar aspirations as Kellogg.”   While more recycling solutions are in the works, flexible plastics made of high-density polyethylene (HDPE) and low-density polyethylene (LDPE) can be recycled through the store drop-off locations.   In addition to the How2Recycle store drop-off logo that Kellogg has placed on the back of its Bear Naked bags, the brand designed a separate Recycle Ready logo to educate consumers. Kellogg also revamped its Bear Naked website, which has a link to the store drop-off program and locations.   The brand also kicked off a social media campaign on Instagram, where followers are most interactive. Moore took the campaign a step further by posting a video on her personal LinkedIn page of her collecting different types of plastics and showing people how the store drop-offs work, she says.   “We were having people taking pictures of themselves dropping off the bag and showing people they’re at Target and you can drop this off here now,” Moore says. “It’s really simple. We get a lot of comments from people saying, ‘Hey, I didn’t know this. When did you guys start doing this? This is great.’”

Dyper, the eco-friendly diaper service is fulfilling its promise to create the best diaper for babies, parents, the planet and wallets by introducing the first compostable diaper offered in the over $48 billion industry. The company has announced its partnership with TerraCycle to implement the Redyper composting program in the U.S., making it turnkey for existing and new subscribers to return their soiled-diapers for composting.   Though composting Dyper diapers at home has always been possible, the TerraCycle partnership allows families to skip the DIY and help ensure that their used diapers don’t add to the more than 20 billion diapers filling landfills in the U.S. yearly. Dyper provides an environmentally-sound, cost-effective and convenient way to receive diapers through a monthly subscription. All products are made from responsibly sourced materials that are free of harmful chemicals, prints and scents.   “We’re committed to making diapering effortless for parents, gentle for babies and kind to the planet,” says Sergio Radovcic, CEO of Dyper. “It wasn’t easy to develop the most fully compostable diaper ever created. But, we are thrilled that our partnership with TerraCycle will make it easy for families to keep their used diapers out of landfills.”   Dyper subscribers that opt-in to the Redyper program are provided with bags and a specially designed box engineered to the strictest United Nations Haz Mat shipping standards. When the box is full, subscribers can download a prepaid shipping label from the Dyper Composting Program page found on the TerraCycle website for easy return of their soiled diapers for composting. The waste composted through this program will be used in specialized applications, such as for vegetation in highway medians.   “As the first of its kind initiative, the Redyper Program offers consumers a unique opportunity to responsibly dispose of their soiled diapers, as well as minimize their environmental impact by composting them through TerraCycle,” says Tom Szaky, founder and CEO of TerraCycle. “We are pleased to partner with Dyper to drive awareness of this ground-breaking program.”   The TerraCycle supported Dyper Composting Program is part of Dyper’s ongoing initiative to make eco-friendliness in the baby segment more effective and convenient. Along with being compostable under the right conditions, Dyper’s product is made from responsibly-sourced bamboo and free of chlorine, latex, alcohol, perfumes, lotions, PVC, TBT and Phthalates. Through the brand’s smartphone app, Dyper subscribers can also schedule routine deliveries, request expedited shipments in as little as two hours, or ship-back unused diapers.  The entire diaper journey is counterbalanced through carbon offsets purchased by Dyper on behalf of subscribers. Learn more about the program by visiting dyper.com/redyper.  For a limited time, REDYPER opt-in will be free with a monthly subscription of Dyper.  Following the limited time offer, Redyper will require a monthly maintenance fee of $39.

Halloween is far behind us, but the collection of packages of sunk candy continues at LaRocque School. Teacher Dominique Hébert has established a partnership with the company Avrac A'davrac in order to pick up these papers which cannot be recovered. The initiative had a lot of talk in October: the co-founder of Effect PH, Hélène Boissonneault, had collected in some forty drop-off points all these types of packaging (chocolate bars, chips, etc.) by handing them over to TerraCycle , a company which gives a second life to this type of waste.  Each class has its basket and a student is responsible for emptying it. "The children made video capsules to find out what to put in the box," says the teacher, who took care of the project at Halloween.  The teacher, who had difficulty finding a budget for the project, approached various organizations before Avrac A'davrac agreed to sponsor the school box. “What we said to each other is that we are training citizens, we want them to be eco-responsible. We want to make them aware of the environment, to pay attention to the planet, because we don't have planet B! " The children wrote humorous scenarios for the broadcasting of the capsules. Dominique Robert advocates for a better integration of environmental protection in schools. “The ecological aspect is up to our motivations. I think schools have to rethink that, ”she illustrates, giving the example of a budget for ecological initiatives. This place of the environment is all the more important as the ecological footprint of schools is large, she underlines by adding that certain initiatives should extend to all schools. "Is it up to us to do it?" Yes, as citizens, but how can we make institutions responsible so that it becomes collective and community action? "  The presence of collection boxes on Halloween had the effect of raising awareness among the children, who had not yet wondered about the fate of their candy, chocolate or other packaging. "I never looked if we could put them in recycling," says Iona Gendron.  Owner of Avrac A'davrac, François Vincent notes that the initiative launched during Halloween week has indeed made people aware of what is happening with their packaging. “It gives a visual when you see tons and tons of garbage bags. It’s tangible. It's a huge amount of plastic, it makes you aware of that ... "However, we must pay attention to the opposite effect, notes Mr. Vincent, recalling that it is not because we can now recycle these packaging that we must encourage their consumption, the objective being to reduce at the source. Mr. Vincent believes that it is through laws and regulations that things can change. The grocery store now offers its customers the possibility of paying $ 20 per year to dispose of their non-recyclable packaging in order to send it to Terracycle.  Dominique Hébert specifies that other projects are underway. It wishes to install three-way bins, to recover paper and cardboard, plastic and non-recoverable packaging intended for TerraCycle. "We are going to apply for financial assistance from the School Board Foundation," she said, stressing the importance of getting children used to sorting materials.  

02.19.20 Dyper, the eco-friendly diaper service is fulfilling its promise to create the best diaper for babies, parents, the planet and wallets by introducing the first compostable diaper offered in the over $48 billion industry. Today the company announces its partnership with TerraCycle to implement the Redyper composting program in the U.S., making it turnkey for existing and new subscribers to return their soiled-diapers for composting. Though composting Dyper diapers at home has always been possible, the TerraCycle partnership allows everyday families to skip the DIY and help ensure that their used diapers don't add to the more than 20 billion diapers filling landfills in the U.S. yearly. Dyper provides an environmentally-sound, cost-effective and convenient way to receive diapers through a monthly subscription. All products are made from responsibly sourced materials that are free of harmful chemicals, prints, and scents.   "We're committed to making diapering effortless for parents, gentle for babies and kind to the planet," says Dyper CEO Sergio Radovcic, "It wasn't easy to develop the most fully compostable diaper ever created. But, we are thrilled that our partnership with TerraCycle will make it easy for families to keep their used diapers out of landfills." Dyper subscribers that opt-in to the Redyper program are provided with bags and a specially designed box engineered to the strictest United Nations Haz Mat shipping standards. When the box is full, subscribers can download a prepaid shipping label from the Dyper Composting Program page found on the TerraCycle website for easy return of their soiled diapers for composting. The waste composted through this program will be used in specialized applications, such as for vegetation in highway medians. "As the first of its kind initiative, the Redyper Program offers consumers a unique opportunity to responsibly dispose of their soiled diapers, as well as minimize their environmental impact by composting them through TerraCycle," says Tom Szaky, founder and CEO of TerraCycle. "We are pleased to partner with Dyper to drive awareness of this ground-breaking program. "The TerraCycle supported Dyper Composting Program is part of Dyper's ongoing initiative to make eco-friendliness in the baby segment more effective and convenient. Along with being compostable under the right conditions, Dyper's product is made from responsibly-sourced bamboo and free of chlorine, latex, alcohol, perfumes, lotions, PVC, TBT, or Phthalates. Through the brand's smartphone app, DYPER subscribers can also schedule routine deliveries, request expedited shipments in as little as two hours, or ship-back unused diapers.  The entire diaper journey is counterbalanced through carbon offsets purchased by Dyper on behalf of subscribers. Interested consumers can learn more about the program by visiting dyper.com/redyper.  For a limited time, Redyper opt in will be free with a monthly subscription of Dyper.  Following the limited time offer, Redyper will require a monthly maintenance fee of $39.

02.19.20 Dyper, the eco-friendly diaper service is fulfilling its promise to create the best diaper for babies, parents, the planet and wallets by introducing the first compostable diaper offered in the over $48 billion industry. Today the company announces its partnership with TerraCycle to implement the Redyper composting program in the U.S., making it turnkey for existing and new subscribers to return their soiled-diapers for composting. Though composting Dyper diapers at home has always been possible, the TerraCycle partnership allows everyday families to skip the DIY and help ensure that their used diapers don't add to the more than 20 billion diapers filling landfills in the U.S. yearly. Dyper provides an environmentally-sound, cost-effective and convenient way to receive diapers through a monthly subscription. All products are made from responsibly sourced materials that are free of harmful chemicals, prints, and scents.   "We're committed to making diapering effortless for parents, gentle for babies and kind to the planet," says Dyper CEO Sergio Radovcic, "It wasn't easy to develop the most fully compostable diaper ever created. But, we are thrilled that our partnership with TerraCycle will make it easy for families to keep their used diapers out of landfills." Dyper subscribers that opt-in to the Redyper program are provided with bags and a specially designed box engineered to the strictest United Nations Haz Mat shipping standards. When the box is full, subscribers can download a prepaid shipping label from the Dyper Composting Program page found on the TerraCycle website for easy return of their soiled diapers for composting. The waste composted through this program will be used in specialized applications, such as for vegetation in highway medians. "As the first of its kind initiative, the Redyper Program offers consumers a unique opportunity to responsibly dispose of their soiled diapers, as well as minimize their environmental impact by composting them through TerraCycle," says Tom Szaky, founder and CEO of TerraCycle. "We are pleased to partner with Dyper to drive awareness of this ground-breaking program. "The TerraCycle supported Dyper Composting Program is part of Dyper's ongoing initiative to make eco-friendliness in the baby segment more effective and convenient. Along with being compostable under the right conditions, Dyper's product is made from responsibly-sourced bamboo and free of chlorine, latex, alcohol, perfumes, lotions, PVC, TBT, or Phthalates. Through the brand's smartphone app, DYPER subscribers can also schedule routine deliveries, request expedited shipments in as little as two hours, or ship-back unused diapers.  The entire diaper journey is counterbalanced through carbon offsets purchased by Dyper on behalf of subscribers. Interested consumers can learn more about the program by visiting dyper.com/redyper.  For a limited time, Redyper opt in will be free with a monthly subscription of Dyper.  Following the limited time offer, Redyper will require a monthly maintenance fee of $39.

There are all sorts of cautions and restrictions that go along with home-composted diapers, and eco-friendly diaper service DYPER teamed up with TerraCycle to create a compostable diaper program. With REDYPER, new and existing DYPER subscribers can return soiled-diapers for composting, which saves them the burden of having to come up with the appropriate composting solutions on their own or contribute to landfill waste. DYPER's diapers are made with responsibly sourced materials that are free of harmful chemicals, prints and scents. Members who opt into the REDYPER program are supplied bags and specially designed boxes that are in accordance with United Nations Haz Mat shipping standards. As part of the program, collected waste will be used for applications like vegetation in highway medians. Image Credit: DYPER    

SCOTTSDALE, AZ, February 19, 2020- DYPER, the eco-friendly diaper service is fulfilling its promise to create the best diaper for babies, parents, the planet and wallets by introducing the first compostable diaper offered in the over $48 billion industry. Today the company announces its partnership with TerraCycle to implement the REDYPER composting program in the U.S., making it turnkey for existing and new subscribers to return their soiled-diapers for composting.   DYPER is an eco-friendly $68 per month diaper subscription service, now launching REDYPER which allows customers to ship back their soiled DYPER diapers for composting.

1. It’s a breakthrough accomplishment.   Kellogg’s Bear Naked Inc. granola division’s develops the first fully recyclable stand-up barrier pouch made for food packaging that’s available nationwide.   2. The pouch rollout involves all Bear Naked core product lines of granola cereal and bites.   Done across some 13 product lines, “all of the granola has already converted over and we are currently in the process of rolling it out on our bites,” Moore discloses.       3. The pouch structure was turned from inconvenient and unconventionally recyclable to conveniently recyclable.   The previous pouch structure was recyclable due to a special an arrangement with Trenton, NJ-based upcycler TerraCycle. While commendable in diverting packaging from landfill, the process wasn’t efficient or convenient: recycling required customers to sign up for a special program to collect, clean and ship the packaging to NJ for recycling otherwise the packaging was trashed by consumers and sent to landfill.   The new packaging can be recycled using convenient at-store drop-off locations in meeting the standards of the Sustainable Packaging Coalition’s How2Recycle program. That information appears along the bottom of the back panel next to a “Recycle Ready” callout.   4. Kellogg’s needed 18 months’ R&D to reinvent the pouch.   According to Moore, validation and shelf-life testing took the bulk of that time.   The new Bear Naked granola packaging is manufactured by Berry Global, which has nine-layer blown extrusion equipment that provides the stiffness and superior sealing for hermetic packaging with gas flushing. Bear Naked also chose Dow Chemical’s RecycleReady technology that enables recyclable film structures (see Bear Naked ends partnership with TerraCycle; develops new recyclable packaging for granola snacks, published May 2019).   The new pouch film is mono-material PE with ethylene vinyl alcohol (EVOH) barrier; the previous structure was a multilayer PET/polyethylene film.   5. The project required an unusual arrangement and strategic partnerships across the entire value chain.   It was managed end-to-end from the resin manufacturing all the way through to the transportation and customer involvement, Moore reports, involving “a lot of collaboration and partnership between the different players depending on their place in the supply chain.”   In addition to resin supplier Dow and film provider Berry Global, other vendors included Presto Products Co. that provided the recycling-compatible Fresh-Lock zipper and printer/converter ColorMasters, based in Albertville, AL.   According to Moore, the direct involvement of a resin supplier was highly atypical of a Kellogg’s packaging development.   Contract manufacturing partner Hearthside Food Solutions, Downers Grove, IL, was also involved, Moore adds.       6. Retaining the look, feel and product quality of the brand was essential.   Surface-printed by ColorMasters, the pouch has a matte finish and a window on the front in line with the previous packaging. A ColorMasters sales manager tells PlasticsToday that it converted rollstock film supplied by Berry Global into printed rollstock for vertical-form-fill-seal packaging and premade pouches for the brand. The process included applying a heat-resistant coating, he added.   “We had to also maintain our existing shelf life in the new film, which appears on the pouch bottom,” Moore adds.   As importantly, she points out that the film’s compatibility with the company’s existing packaging equipment had to be seamless.   7. There’s no “one size fits all” in sustainable packaging.   “Involvement and engagement from all parts of the material spectrum is very important when designing for sustainability,” explains Moore. “It’s really important to understand your consumers’ needs, the level of understanding they have around sustainable packaging and what your vendor partners capabilities are. Also, having a good understanding of the recycling infrastructure in your area or country is important from a design aspect.”   8. Deep learnings were gained.   “This was a very intense project to lead, but if you were to ask anyone on the team, the one theme you would hear is that everyone gained a deep knowledge about another area of the packaging value chain that they didn’t have previously,” Moore reports. “We will all use the experience to help further sustainable packaging design in future project work.”   And from a personal perspective, what was most gratifying for her was “being able to be a part of an important goal for the brand and being able to see it from initial ideation to launch.”   9. The reception has been positive.   In addition to knowing the pouch’s recyclability is a positive step for the environment, the pouch’s innovation has been recognized by the industry: it received the 2019 Technology Excellence Award in Snack and Bakery during Pack Expo in September and in January, the pouch was chosen for a Silver Award in Sustainability in the Flexible Packaging Assn.’s 2020 FPA Achievement Awards.

Can beauty be sustainable? Rose Inc. investigates.

Sustainability can mean a lot of things. It’s a commitment to maintain our natural resources and preserve ecological balance, but even more so, it’s a personal journey to understand that the everyday choices we make—from how we eat and travel, to the products we buy and how we dispose of them—will ultimately determine our collective future. Sustainability is measured by our impact on people, animals, and the planet. In 2020, it often means striving for what’s referred to as a ‘zero impact’ or ‘do no harm’ model where ethical practices replace the destruction, pollution, and exploitation common across many industries. In beauty, sustainability is best assessed by looking at the sourcing of the raw ingredients, the supply chain that brings a product together, and, finally, its packaging. Only when a brand shares its progress with consumers can it call itself transparent, which is a hallmark of endeavoring towards sustainability. Ingredient Sourcing: Where Did This Come From?   Opting for natural ingredients is an admirable first impulse, but the full picture of sustainability is more nuanced. “We need to ask where an ingredient was grown or harvested and what impact it had on the environment and people,” says Christina Archer, a UK-based sustainable sourcing consultant for the cosmetic industry with over 15 years working in communities across Asia, Latin America, and Europe. Take, for example, common oils like palm, argan, and almond. “Mass commercial cultivation of these products often comes with destruction of habitats, degradation of soils, and loss of biodiversity,” Archer says. While using a natural oil is better for the planet than petrochemical alternatives—like petroleum jelly or mineral oil—unless it’s cultivated using fair trade practices, it’s impossible to know if it’s actually sustainable.   Sourcing from animals and marine habitats gets even tricker, which has opened the door for biotech companies like Aprinnova, a Silicon Valley-based leader in technology to synthesize natural ingredients that might otherwise be impossible to environmentally or ethically source. One buzzy ingredient it’s brought to market is an alternative to squalene, a luxurious-feeling, hydrating oil that’s been historically sourced from shark liver.   “We use fermentation to make a precursor of squalene using sugarcane, then we're able to transform that into squalene itself,” says Ashlee Nunes, Aprinnova’s technical sales and product manager. “When you look at our squalene on a molecular level, it’s the same as the one from a shark. As far as efficacy, we’ve done many studies to prove they're very similar.” (Sound familiar? This might remind you of the advancements happening right now in meat alternatives.) Today, Aprinnova’s squalene can be found in its in-house brand, Biossance, as well as many cruelty-free beauty brands around the globe. But synthetic ingredients is just one possible step for the rapidly-growing beauty industry to become more sustainable.   The Supply Chain: How Did It Get To Me?   The initial sourcing of ingredients kicks off the match, but the supply chain is where the game plays out. A 360-degree look is especially important when considering environmental issues and workers’ rights.   Take mica, for example, a naturally-occurring mineral that commonly gives highlighter, eyeshadow, and primer its delicate shimmer. Like many raw ingredients, it’s often sourced and processed in the developing world. Cosmetic-grade mica—although natural and safe for skin—is often mined in India by entire families in unsafe conditions without the consumer ever being aware. Then there is the issue of the environment. Deforestation is often necessary to extract or transport minerals, and fossil fuels are burned to create the energy to process them. It’s a similar issue to diamonds and gold or cocoa and coffee, which makes transparency around the supply chain crucial to achieving sustainability. Tech companies like SourceMap are developing software to bring transparency to hard-to-track ingredients, like mica and cocoa, but until it’s widespread, shopping for products with fair trade ingredients or certifications is one good way to vote for sustainability with your pocketbook.          

Packaging: What Happens After The Consumer’s Done?

  A beauty product’s story doesn’t end with our link; the consumer is much closer to the middle of the chain. From the suds washed down the drain and (eventually) into natural waterways, to the packaging’s second life (which can last for 400+ years for most plastics), true sustainability is more holistic. “[A product’s] end of life is as important as the beginning,” Archer says.   The most obvious solution to sustainably discard something is your curbside recycling bin, which is great for commodity materials, like beverage bottles, paper, and aluminum. “The value of these products covers the cost that's associated with collecting, sorting, and processing them into something new,” says Sarah Teeter, global project manager for TerraCycle, a private U.S. recycling business that specializes in hard-to-recyclable waste. Here’s the catch: “Anything that hasn't been designed with recyclability or recovery in mind is basically deemed non-recyclable in a municipal setting.”   The biggest issue preventing the curbside recycling of beauty products is the very thing that makes them so convenient: mixed materials, like a compact or lipstick bullet made with metal and plastic parts or a plastic pump with a little metal spring. “All those things are really costly to separate, so they're not going to be recovered in the normal recycling ecosystem,” says Teeter.   Luckily, due to consumer interest, refillable makeup is coming back into vogue and packaging companies are starting to respond by using plastic recovered from the ocean. Today, the most sustainable choice is to look for is glass or post-consumer, clear or white packaging, which (due to demand for clear and white plastic over black or brightly-colored plastics by recyclers), is more likely to be taken by your local recycling center.   As for the rest, Terracycle offers a program where consumers can ship non-recyclable products to them for a fee, then, “Our materials department identifies our processing partners to convert that material into a useful new format and find a downstream application for it,” Teeter says. Many brands pay Terracycle to take its products for no cost to consumers (check TerraCycle’s website for details) and many other brands collect empties in stores for commercial recycling. Bottom line: If a product becomes trash, it’s not sustainable, but recycling an empty is often the onus of the consumer.