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Loop's quest for reuse dominance has only gotten more ambitious during the pandemic

"When COVID hit ... what scared me honestly was the deluge of reporters calling saying, 'Should we write off the idea of reuse in an age of contagion?'" he recalled during a panel at the Circularity 20 conference in May. Journalists were referring to the slashing of reuse-refill and "zero waste" initiatives taking place across the corporate world. This, combined with cautionary messaging from the plastics industry, contributed to a narrative that reusable systems — a fledgling industry born out of the desire to avoid disposable products and packaging — may be a risky business. Szaky argues, however, that rather than being a threat to the new reuse economy, the pandemic has ushered in an opportunity to professionalize its services. Launched over a year ago to much hype, the Loop concept — still in its trial phase, but partnering with some of the world's largest CPG companies — has been leading the way in terms of reusable, refillable packaging as a niche business opportunity for the grocery and retail sectors. The last several months have seen not less, but more usage of the Loop service and, as a result, Szaky has pointed to it as a hopeful example for what the post-pandemic future of reuse could look like. Loop's strict cleaning protocols, he says, should quell any fears about contamination and its online portal allows consumers to shop from the safety of home. These features may offer a solution to some of the risks associated with reusable circularity that brands and retailers worry about moving forward. As the world rebuilds in the wake of the pandemic, Szaky and others in the reuse sector are hoping to shift from a movement centered around DIY, consumer-led programs to one more suitable to industrial applications. This may even come in the form of tighter regulations around reusable systems overall. But some say while raising the profile of these systems is a good thing the industry should be careful about narrowing down to market-driven solutions too quickly. Loop, after all, is still an experiment.

Reuse and refill: The model that will help consumers quit single-use plastics

By moving away from disposable packaging, companies can address the global problem of plastic waste. According to the United Nations Environment Programme, only about 9 percent of the 9.9 billion tons of plastic generated globally since the 1950s has been recycled. And almost halfPDF of the plastic waste poisoning marine life, contaminating food, and clogging waterways and sewers comes from consumer packaging. As citizens and governments wake up to this plastic pollution problem, they’re turning to business to solve it. In response, companies are trying to craft new approaches to plastic, whether reducing overpackaging or rolling out biodegradable materials made of seaweed and cornstarch. But one solution — the reuse and refill business model — stands out for its potential to shift consumer behaviors while unlocking new revenue streams and cost savings for companies. It’s easy to see why cheap, sturdy, and lightweight plastic quickly became a convenient, even innovative, packaging option for consumers. The popularity of plastic skyrocketed in developed countries in the 1970s after the invention of the polyethylene shopping bag. Within two decades, plastic packaging had flooded the world; consider how, in developing countries, companies have marketed items as varied as shampoo and hot sauce in tiny single-use sachets. Products in cheap, throwaway packaging solved immediate consumer problems — for example, by offering unbeatable value pricing to millions of low-income consumers — but created a long-term health and environmental disaster. Now, businesses such as Chilean startup Algramo, literally meaning “by the gram,” are tackling the crisis by offering the same value to consumers, but in reusable containers. Algramo makes products including rice, detergent, and other everyday staples available in small, affordable quantities via smart vending machines and reusable containers. Its bottles are equipped with RFID tags that allow consumers to earn discount credits with each use, incentivizing them to refill rather than throw away the containers. Flush with funding from Closed Loop Partners, Algramo is set to introduce this innovation in the U.S., too. It has good reason to do so: On a per capita basis, North America, Japan, and Europe generate the most plastic waste. Algramo is in good company. As part of the New Plastics Economy initiative, launched two years ago by the Ellen MacArthur Foundation and the U.N. Environment Programme, more than 400 organizations have set concrete targets toward reducing plastic use by 2025. Many of those companies, both startups and established brands, are testing reuse and refill solutions. Their motivations aren’t strictly altruistic: The Ellen MacArthur Foundation estimates a US$10 billion business opportunity in converting even 20 percent of global plastic packaging to a reusable model.  

Ulta launches Conscious Beauty initiative

Dive Brief:

  • Ulta on Tuesday announced the creation of Conscious Beauty, an initiative that will launch in the fall and certify beauty brands under five pillars: clean ingredients, cruelty free, vegan, sustainable packaging and positive impact.
  • The clean ingredients label will certify that a brand meets Ulta's "Made Without List," which consists of parabens, phthalates and other ingredients from over 25 chemical categories, according to a company press release.
  • As part of the sustainable packaging initiative, which highlights brands made with reduced, recyclable or refillable packaging, Ulta will pilot a "circular shopping experience" with Loop. The beauty retailer is also pledging that 50% of all packaging sold by 2025 will be recyclable, refillable, or made from recycled or bio-sourced materials.

Dive Insight:

In the midst of a pandemic that has threatened to put many things on the back burner, including sustainability initiatives, Ulta Beauty has announced a wide-ranging effort to hold itself accountable to more conscious practices. The beauty retailer set its first sustainable packaging goals as part of the initiative, and partnered with various third parties for the certification process, including ClearForMe to verify brands have clean ingredients, and PETA, Leaping Bunny and Choose Cruelty-Free to help certify cruelty-free brands. The company also established a Conscious Beauty Advisory Council to "ensure accountability and drive the initiative forward." Currently, the council includes CEO and co-founder of Loop, Tom Szaky, and co-founder and COO of Credo Beauty, Annie Jackson, among others. A partnership with Credo Beauty was announced by Ulta in June, and the clean beauty collection, dubbed the Credo Collection, will launch within the conscious beauty platform. While all of the certifications are meant to help customers identify brands that share their values, it's the sustainable packaging initiative that Ulta itself is committing the most to. In addition to setting a 50% sustainable packaging goal, the retailer also plans to support the Sustainable Packaging Coalition, and will use How2Recycle instructions on its owned brand packaging and print materials. Ulta is hitting on some of the biggest issues in the beauty space, and retail more broadly, with this launch. For years, the level of waste created by retail packaging has been scrutinized, and retailers have turned their focus to tackling that and other major sustainability issues, including making products with more sustainable materials and building up the circular economy. Loop is one of the companies at the forefront of sustainable packaging, partnering with companies like Procter & Gamble, Unilever and Kroger in 2019 to test out refillable packaging solutions. Clean and sustainable beauty initiatives have also grown to define the beauty space in recent years, with Sephora launching a Clean at Sephora category in 2018 and Neiman Marcus debuting an online shop centered around clean beauty products in 2019. Even big-box players like Walmart and Target have added brands to their assortment that focus on clean ingredients. "As the beauty retail leader, we have the unique opportunity to inspire positive change in our industry," Dave Kimbell, president of Ulta Beauty, said in a statement. "With Conscious Beauty at Ulta Beauty, our focus is to educate, guide and simplify product choice and elevate those brands doing good for our world. This initiative helps our guests readily navigate our assortment through the lens of what matters most to them."

How Beauty Brands are Taking a More Sustainable Approach to Packaging and Products

We can’t shop our way to saving the planet, but mindful choices matter. From ingredient sourcing to sustainable packaging, here’s how the industry’s forward thinkers are striving to tread more lightly as they produce the beauty products you see on the shelves. RETHINK (INGREDIENTS) The fine print on beauty labels tells us next to nothing about how responsibly sourced ingredients are. To muddy matters, calculating a product’s eco-footprint is far trickier than checking if the formula is all-natural or organic. For starters, natural ingredients can still cause environmental havoc—take, for instance, palm oil and its derivatives. Widely used in beauty products, they can be found in everything from shampoo to lipstick. They are largely produced in Indonesia and Malaysia, and the destruction of rainforests to clear the way for palm oil plantations is rampant. “A lot of companies are coming in and bulldozing and forcing communities out,” says Lindsay Dahl, senior vice-president of social mission at Beautycounter. Although the brand initially wanted to eschew palm oil, it realized that palm derivatives are still the best choice for many of its products.

The pandemic could have ruined this sustainable business. But instead, it's expanding nationwide.

When the coronavirus pandemic hit the United States, local governments and big companies quickly changed their tune on reducing single-use plastics. They started prohibiting cloth totes in grocery stores and rejecting reusable coffee mugs at cafes. They embraced disposables once again, seeing them as the safer, more hygienic option.
Maine delayed its plastic bag ban from April 2020 to January of next year. San Francisco in March instructed businesses to bar customers from using their own bags, mugs or other reusable items in order to promote social distancing. Meanwhile, Starbucks (SBUXstopped allowing people to use their own mugs, and McDonald's (MCDdecided to close self-serve soda fountains as it reopens its doors.
For Loop, a shopping service that sells items from Häagen-Dazs ice cream to Tide laundry detergent in reusable packages rather than the single-use containers that normally hold the products, consumer fears around reuse could pose an existential threat. But instead of retreating during the pandemic, the project has reported sudden increases in sales and is about to expand in a big way. Loop, which launched as a pilot last year in the Northeastern US and Paris, is planning to expand to the 48 contiguous states by July 1.

Loop to Launch E-Comm Platform Nationwide

Loop products in returnable packaging are scheduled for launch nationwide this month, while retail partners in the U.S., France, and Japan plan to offer Loop in their stores later this year. For those consumers going the e-commerce route, there is a $20 shipping fee for orders under $150. In addition, the tote used to deliver and return product comes with a $15 deposit fee. For those consumers going the e-commerce route, there is a $20 shipping fee for orders under $150. In addition, the tote used to deliver and return product comes with a $15 deposit fee. As of presstime, consumers across the U.S. who are interested in shopping online for a range of grocery, household, and personal care products in gorgeously designed, durable, and resusable packaging will have the chance in June, when Loop launches nationwide. Since May 2019, the ground-breaking Loop circular shopping platform has been available in 10 states in the Northeast and in Paris. According to Tom Szaky, founder of recycling company TerraCycle and of Loop, the 10-month pilot allowed participating Consumer Packaged Goods companies, retailers, and Loop itself to gain insights and tweak the program for wider availability. Just as exciting, if not more so, according to Szaky, is the news that Loop will be launching in retail stores, including Kroger in the U.S., Carrefour in France, and AEON in Japan, later this year. Currently 400 brands have joined Loop, 20% of which are now available for purchase on Loopstore.com and 80% of which are still in development. Says Szaky, it can take a CPG anywhere from six to 18 months from the time they join Loop until they have product ready to ship. Among some of the more well-known CPGs that have signed on are Seventh Generation, Clorox, Procter & Gamble, Nestlé, Unilever, and Mars Petcare. Loop also sells a “private-label” brand, Puretto, which Szaky says is being used by name-brand companies to test products on the platform while they develop their own, unique version. “As soon as that version is live, we disable the Puretto version,” he explains. Szaky notes that the rapid speed of the nationwide launch—Loop was only just unveiled in February 2019—is due to the fact that “it’s a platform and not a producer or retailer.” He continues, “By being a platform, it is really our fantastic brand partners that are doing all the production and ramping up, and the retailers that are doing the scale up and later the in-store deployments. What we really have to ramp up is the ability to accept that used packaging, sort it out, and clean it. And that’s an area that TerraCycle has almost two decades of experience doing in disposables. Now we just have to bring the same experience to reusables.” With the e-commerce model, all packaging—both filled and empty—is handled through Loop’s Northeast location, from which it sends orders to consumers and where it cleans the empty packaging. Loop will also soon be adding another location on the West Coast. “As the stores move into bigger and bigger volumes, we will deploy in total seven major facilities in the U.S.,” Szaky says. “I expect that to take about two to three years.” Outside the U.S., Loop has one facility in each country in which it operates and is planning to add more. When the in-store platform becomes available, CPGs will supply the stores with product directly. Then, when consumers are through with the product, they will drop off the empty packaging at the store, and Loop will pick it up for cleaning. For those consumers going the e-commerce route, there is a $20 shipping fee for orders under $150. In addition, the tote used to deliver and return product comes with a $15 deposit fee. Deposits are also required for every package and range anywhere from $1.25 for a glass liquid soap dispenser bottle from Soapply, for example, up to $10 for a rust-resistant metal container with one-touch dispensing lid for Clorox disinfecting wipes. One of the biggest learnings from the Loop pilot says Szaky is that the deposit costs have not deterred consumers from using Loop. “I thought they would be, but they haven’t in any capacity,” he says. “Even deposits as high as $10 have not been a deterrent. So we’re very, very happy about that.” Not only that, Szaky says, but they also found that within 90 days of purchase, there was a 97% return rate for the packaging by consumers. “I was surprised, but I think it has to do with the fact that people want the product inside, and they’re happy to have us professionally clean it and have it professionally refilled so they can access it again.” For the in-store business, the only deposits are for the containers, which consumers are refunded when they return the empty packaging to the store.  

Plastics in the time of pandemic

TO RECYCLE OR REUSE? — Tom Szaky isn’t rooting for the collapse of the recycling business — but he is prepared to capitalize on it. Szaky, founder of reusable packaging startup Loop, is trying to persuade Americans to return to the days of the milkman, only this time shampoo, peanut butter and ice cream would arrive on doorsteps in specially designed containers and the empties returned for refills. “When less things become recyclable, our relevance increases,” Szaky tells The Long Game. “We’re a reaction to a failing recycling system.” Loop works with brands including Procter & Gamble, Unilever, Nestlé and Mars to create durable packaging that Loop cleans and sells back to them. Kroger plans to begin selling Loop products in some of its West Coast grocery stores by the end of this year, and Walgreens stores on the East Coast will join next year, Szaky says. The company is valued at $100 million, with more than 100,000 customers so far on its online testing platforms.

Companies will have to get creative to advance sustainability amid crisis

Before COVID-19, people all over the world had been more focused than ever before on the issue of sustainability. Coordinated climate strikes, beginning in the spring of 2019 and continuing through the end of that year, conveyed the growing environmental concerns of global citizens. Employees and customers had increasingly expressed an interest in businesses taking stances and action on sustainability. And consumer data showed rising salesPDF of products with sustainability features.   Fast forward to today: The pandemic has exposed the fragility of the world and heightened people’s appreciation of sustainability. How many of us have appreciated cleaner air and paid more attention to labor conditions, given essential workers’ greater virus exposure? Consumer insights reflect this sensitivity. More than half of respondents to a recent survey conducted by management consulting firm Kearney said that as a result of their COVID-19 experience, they are more likely to buy environmentally friendly products. And unpublished PwC research shows that 75 percent of U.S. consumers surveyed believe companies should maintain changes they’ve made due to COVID-19 that have a positive environmental impact. At the same time, though, the deep economic crisis the virus has caused is making shoppers more price-sensitive and forcing many companies to do whatever it takes to simply stay afloat. Companies, even those with sustainability in their DNA, might put some or all environmental, social, and governance (ESG) initiatives on hold to stem revenue losses. However, early data suggests that prioritizing sustainability could boost financial performance. As of early April, big ESG-focused funds were outperforming the S&P 500 for the year to date. This could reflect investors’ long-term view. Recent research by the Conference Board also highlights how a commitment to sustainability can help companies weather crises and recover faster. Companies will need to be creative and more focused than ever, though, to make their sustainability strategies financially viable, considering reduced corporate income and consumers’ renewed frugality. Long before the pandemic, Unilever’s chief research and development officer, Richard Slater, highlighted companies’ lead role in mainstreaming sustainability when he said in an interview on NPR, “The onus is on us as consumer companies to innovate and come up with solutions that are great for people…[and]…convenient at the right price.”

Evidence that consumers care

A growing number of consumers — along with employees and investors — want to associate with brands whose values they identify with. According to a global consumer survey by the Conference Board, about two-thirds of respondents have bought brands because of their environmental practices, more than half have dropped brands because they don’t provide fair labor conditions, and a significant share have at some point either switched brands or moved away from brands because of the social causes they support. Dichotomy in consumer motivation — between caring about a cause but also about functional features and price — makes pursuing a sustainability agenda complicated. Soon-to-be-published global PwC research shows that consumers think government bears the biggest responsibility for encouraging sustainable behaviors and lifestyles. Those surveyed put themselves in second place, right after the government and ahead of manufacturers/producers, retailers, and other institutions. The survey also found an increase in the number of people making sustainability-conscious decisions year over year. The percentage of survey respondents who avoid plastics when possible rose from 41 percent to 45 percent, and the percentage of those who consciously choose sustainable ways to travel rose from 28 percent to 32 percent. People’s purchasing choices don’t always fall in line with their attitudes about sustainability, but recent purchase data indicates that in some categories, words and actions more or less align. In the U.S., the percentage of overall store sales made up of sustainable consumer packaged goods (CPG) grew from 19.7 percent in 2014 to 22.3 percent in 2017, and is expected to reach 25 percent by 2021. Sales of products with on-package sustainability claims, such as USDA Organic or “no phosphates,” grew almost six times fasterPDF than conventional products from 2013 to 2018 (up 29 percent), accounting for about half of all CPG growth despite the category’s small market share. However, the Conference Board’s global consumer research shows that shoppers have considered sustainable features to be more an appreciated bonus than a core purchase driver. For example, environmental impact ranks only fifth among surveyed consumers’ decision criteria for daily mode of transportation, after speed to destination, cost, convenience, and safety. As Warby Parker cofounder and co-CEO Neil Blumenthal put it in an interview with Inc. magazine, “While customers certainly love the fact that we give back, at the end of the day, it’s not a critical factor in deciding whether to buy a pair of glasses.”

How companies can respond

This dichotomy in consumer motivation — between caring about a cause but also about functional features and price — makes pursuing a sustainability agenda complicated. Yet, doing so can help to differentiate a brand, delight customers, and ultimately create brand and financial value. Those looking to market sustainable offerings should consider the following suggestions. Couple sustainability features with other benefits. Companies can innovate, creating sustainable products and services superior to unsustainable alternatives. For instance, recycling company TerraCycle offers a circular packaging and delivery system called Loop that sends customers products in well-designed containers that can be returned for cleaning and reuse. Many companies, including leading ice cream, shampoo, and mouthwash brands, are part of the program. Consumers have to pay a deposit that’s sometimes double the product price, but people don’t mind. Why? Two-thirds of Loop shoppers indicate that the higher-end aesthetics and functionality of the containers are actually more important to them than the program’s sustainability benefits. For example, Häagen-Dazs’s dual-layered Loop cups keep ice cream frozen but aren’t too cold to hold comfortably, and the containers’ rounded bottom corners makes scooping easier. The fact that the Loop system is eco-friendly is a bonus. Paul Gaudio, global creative director for Adidas, explains the sustainability-as-a-bonus philosophy this way: “I don’t want people to buy it because it’s recyclable. I want people to buy it because it’s awesome. And oh, by the way, it’s recycled.” Minimize the sustainability price premium. Price can deter people from buying sustainable offerings, according to the Conference Board’s research. And in this time of pandemic-induced crisis, with many consumers suffering financial losses, this might be truer than ever. So, achieving cost efficiency is critical to keeping prices low. Companies can do this through innovation and partnerships — including with competitors. For example: Even pre-crisis, Procter & Gamble, Unilever, and Colgate-Palmolive were committed to making their discoveries and technologies for recycling plastics accessible to others in the industry. This helps increase the supply of recycled plastics for all participating companies, while saving other businesses needless development costs. Plus, it advances companies’ sustainability goals and addresses consumer interests. Companies can also launch pricing plans that reward repeat purchases of sustainable products or services. Take Adidas’s circular economy service, Infinite Play, which is available in the U.K. and gives people gift cards or loyalty club points in exchange for their used Adidas items. Educate consumers about sustainability features and build trust. Many consumers find it time-consuming to gather information about a brand’s sustainability features — additionally, they don’t trust claims, or they find them confusing. According to the Conference Board’s survey, this lack of understanding is a key barrier to consumers buying sustainable brands, especially when it comes to awareness of fair labor conditions and wages. So, brands need to clearly communicate with their customers in concrete terms, disclosing information such as the amount of packaging saved or how they’ve enhanced certain working conditions. The COVID-19 crisis has inspired companies to do exactly that: It has put employee-related policies and crisis response in the spotlight, so businesses across the board have been communicating frequently with the public about these issues. To strengthen consumer awareness and trust, companies can also seek independent certification and inclusion in app-based directories that provide information about products’ sustainability features. Give sustainable consumption social currency. Like luxury goods, sustainable products often involve premium quality, craftsmanship, storytelling, and significant intangible value. For example, two different in-store experiments, one with fair trade–labeled coffee and another with a socially conscious–labeled Banana Republic women’s suit  — ordinary items, but not the cheapest in their categories — showed that the sustainability labels enhanced demand. Sustainability features also seem to grant emotional benefits, including the satisfaction of consuming more consciously and subtly signaling status. Brands can support, facilitate, and even encourage this status signaling with tools similar to virtuous behavior badges, such as “I voted” stickers, pink ribbons, or fitness trackers. For example, research has shown positive effects on hotel guests’ towel reusage when they can show their “green support” by wearing a pin or hanging a card on their door. All crises offer new opportunities. The current one may be a test for sustainability, but it could also instigate a new level of corporate creativity and innovation along the sustainability value chain.

CPGs Retool to Get Into the Loop

While there’s no scientific evidence to support this claim, there’s a widely shared consensus that most people eat ice cream directly out of the container. While a seemingly unimportant detail in the production of this popular dessert, for Nestlé, it was one of the most critical considerations as it planned out a new, radical design for its Häagen-Dazs ice cream brand. In January of 2019, Nestlé announced a partnership with TerraCycle, a global recycling organization that was rolling out a first-of-its-kind home delivery service called Loop. TerraCycle, known for its mission to eliminate waste by creating new products from the collection of hard-to-recycle materials, has been around for two decades. Last year, during the World Economic Forum in Davos, Switzerland, TerraCycle founder Tom Szaky unveiled Loop, a shopping platform that will enable people to consume products in customized, brand-specific, durable packaging that is collected, cleaned, and refilled. As the world shines a spotlight on sustainability initiatives that factor in recycling single-use packaging, Loop takes the eco-friendly, green model to the next level by introducing reusable containers. And some of the biggest food and beverage and consumer package goods (CPG) companies including Unilever, Procter & Gamble, Clorox, Mars, Coca-Cola, PepsiCo, Nestlé, and more, were onboard for the pilot program that launched last year. For its part, Nestlé joined Loop as it committed to expanding its global efforts to develop new packaging designs that minimize the impact on the environment, noting that by 2025 the company plans to make 100% of its packaging recyclable or reusable. As part of the Loop pilot program, Häagen-Dazs ice cream was delivered in a reusable, stainless-steel, double-walled ice cream container, which keeps product fresh and cold while maintaining the pint at a comfortable temperature for the person eating the ice cream straight from the container. The design also enables the ice cream to melt quicker at the top, and its rounded edges means the last spoonful doesn’t get stuck in the corners of the container. “The package design process was a critical part of the entire Loop process,” said Steve Yeh, a project manager at Häagen-Dazs. “It’s not just about making a reusable container, it’s also about creating a high-touch consumer experience.” According to Yeh, the Häagen-Dazs package went through a total of 15 iterations before it finally launched. “Nestlé committed major resources to design and develop the original package.” The team also worked closely with Loop on developing breakthrough cooling technology for the Loop Tote, which the ice cream container is delivered in via UPS. Terracycle officials admit there is a cost to manufacturing partners committing to Loop—from the investment in new durable packaging to the design of the product to the time spent understanding how to handle new packaging lines and how to scale to meet demand. But the reality today is that sustainability efforts are here to stay. And any new endeavor is going to require an upfront investment. According to a new business intelligence report from PMMI, the Association for Packaging and Processing Technologies (and Automation World parent company), packaging sustainability has moved beyond a trend and is now a global shift. Released in March 2020, the report, “Packaging Sustainability: A Changing Landscape,” reveals how sustainable packaging initiatives at CPGs are affecting machines, materials, and packaging formats. The report states that the global sustainable packaging market reported that total value of revenue was estimated at $220 billion in 2018 and is predicted to reach $280 billion in 2025, growing at a compound annual growth rate of approximately 6%. The report is based on information collected from 100 sources and 60 interviews. The majority of the CPGs interviewed are looking to switch to lighter weight, recyclable, and sustainable materials to reduce waste. About 36% of the CPGs interviewed are exploring the circular model of reuse/return/refill. The circular economy For decades consumers have been participating in the “throwaway lifestyle,” where single-use products are disposed of resulting in massive amounts of waste. According to the Environmental Protection Agency, the total generation of municipal solid waste (MSW) in 2017 was 267.8 million tons or 4.51 pounds per person per day. Of the MSW generated, more than 94 million tons of MSW were recycled and composted, equivalent to a 35.2% recycling and composting rate. In other words, we don’t have a good track record for recycling. TerraCycle thought there must be another way—which is Loop. “The genesis of Loop is a tighter, closed-loop system that has manufacturers taking back ownership of their packaging,” said Ben Weir, Loops’ business development manager for North America. “It’s bringing about the reusability of packaging in something that is durable and long-lasting and that can be cleaned and used hundreds of times.” It’s not a new concept, but rather a throwback to the milkman model in which consumers returned the glass containers. What’s new is the aesthetic benefits that will drive consumer brand perception—and, while not obvious at first—it is a better economic model for the manufacturer. “The concept of a circular economy is an economic model, not a sustainability framework,” said Tim Debus, president and CEO of the Reusable Packaging Association (RPA). “By decoupling growth from the consumption of finite resources, maintaining product values at their highest, and building market resilience to source material disruptions. It is estimated that the circular economy offers $4.5 trillion of value from new growth and innovation opportunities, and the world today is only 8.6% circular.” There is an enormous opportunity, but manufacturers may hesitate due to the upfront investment related to packaging design and retooling machinery. According to Nestlé’s Yeh, the company used its Bakersfield, Calif., facility to ramp up its production of ice cream in reusable and durable containers for the Loop pilot project. “We decided to retrofit an existing line to support the platform versus investing in a new line. It was not an easy changeover and required some reengineering. Some of the changes involved installing more modern equipment including better code daters and more modern metal detection.” Yeh said they also incorporated improvements to existing processes, which requires additional staff to handle the containers. “Once the platform expands, we would then visit a fully automated system.”
 
Automating the Loop The Loop circular platform works like this: Consumers buy a product online through the Loop store or at a retail location—Nestlé will offer Loop containers in more than 200 Häagen-Dazs shops across the U.S. this year, and Kroger and Walgreens have partnered with Loop to offer products in retail stores later this year. The customer pays a small, fully refundable one-time deposit to “borrow” the package. The delivery is then scheduled online when the customer checks out and pays for shipping to have the Loop Tote filled with product delivered, via UPS, to the customer’s doorstep. When the containers are empty, the consumer puts it back into the Loop Tote and schedules a pick-up. The containers are sent to a Loop facility to be cleaned using state-of-the art cleaning technology and are then sent back to the manufacturer to be refilled. If a consumer purchases ice cream through the Loop subscription, for example, Nestlé fills the sanitized steel container in its Bakersfield, Calif., facility and ships it back to TerraCycle to fulfill the e-commerce orders. Loop is operating the entire supply chain to ease the burden on partners, Weir said, but right now the circular Loop is a largely manual process. “There is tremendous opportunity for technology advancements to be made whether it is IoT (Internet of Things) or [other] levels of traceability in the system, there is definitely opportunity there,” he said. RPA’s Debus agreed, noting that the ability to put some kind of tracking technology on an individual package could become a vehicle for inventory management (where the product is), predictive analytics (when the container will come back), and monitoring for quality control, traceability, and recall capabilities. A lot of the tracking technology available today, such as RFID tags, are outfitted on large pallets or containers used in transporting products, but there are new offerings available now that provide real-time visibility of returnable assets without building out an RFID infrastructure. Roambee, for example, provides an “infrastructure-less sensing platform,” called the Honeycomb IoT Application Programming Interface (API) Platform, that uses Bluetooth, a cellular network, or ultra-low power radios to send data directly to the cloud where it can be analyzed. Of course, it may not make sense to equip every container of Häagen-Dazs with a sensor, and that doesn’t have to happen. “We don’t do 100% tagging, but we do 100% extrapolation of data,” said Vidya Subramanian, Roambee co-founder and vice president of products, noting that it does not have to be a sensor. The tracking method could be as simple as a QR code. “Location helps derive context. If it’s at a cleaning facility you can extrapolate that location to action, like it is available for filling. We take location and assign context to it.” The Honeycomb platform does three things: drive compliance of expected action, drive performance in terms of velocity and movement, and keeps the brand secure—making sure that the product has not been compromised in the chain of custody. Preparing the packaging line Of course, before CPGs can even think about tracking containers, they must first think about switching over lines to accommodate new kinds of packaging—be it durable goods or light-weight materials. According to Rich Carpenter, general manager of product development at Emerson Automation Solutions, three things have to come together to enable trouble-free line changeovers. “The manufacturer has to buy in to modular manufacturing and demand it from their suppliers. The control suppliers have to embrace plug-and-play technology so that when the system arrives on site it can easily plug into whatever automation is there be it PLC [programmable logic controller], SCADA [supervisory control and data acquisition], or DCS [distributed control system]. And the OEM has to make equipment in a way that is more reconfigurable and easier to do product changeovers so as needs change the equipment can adapt to it.”
These things are starting to converge, and, as PMMI’s Packaging Sustainability report points out, there is a real opportunity for machine builders to be proactive now to help manufacturers meet their sustainability packaging goals. Loop is one option for manufacturers trying to make good on sustainability promises. And it seems to be catching on. “We’ve moved from 25 global brands to 150 global brands in a year’s time,” Weir said. “And the idea of an elevated offering is resonating with the consumer.” Manufacturers, too, are thinking about how Loop can be applied upstream, as well. “Working with TerraCycle has challenged our way of thinking across the board,” Nestlé’s Yeh said. “We are currently exploring new avenues to reduce our own single-use packaging across our supply chain. For example, we’re working more closely with our suppliers to receive our ice cream ingredients in reusable containers.”

Reusable CPG Packaging Platform Loop Expands Nationwide

In the midst of the COVID-19 pandemic, many high-profile sustainability initiatives have taken a back seat to single-use packaging, with many grocery stores banning reusable bags and Starbucks no longer accepting refillable mugs. Despite this, Loop is going all in on reusable packaging, launching its waste-free CPG delivery platform nationwide through retailers Walgreens and Kroger with heavyweight brand partners including PepsiCo, Nestlé and Unilever. Loop, which launched a pilot last spring in New York and Paris, sells products like Nature’s Path granola and Haagen Dazs ice cream, with products from beverage brands like Chameleon Cold Brew and Tropicana currently in development. It also offers household and personal care items from companies like Procter & Gamble and The Clorox Company. The products are offered in reusable jars and containers delivered to consumers in a reusable tote, and when the containers are empty, consumers pack them up in the tote and schedule a pickup with partner UPS, who sends them to be cleaned and sterilized. If consumers have a subscription (about 30% of Loop users do), returning a container triggers the purchase of a new item to be sent. Non-subscribers put down a small deposit on the container and get it back when it’s returned. “Loop tries as best as it can to emulate the convenience of disposability to make it feel like a disposable system,” said Loop CEO Tom Szaky, who is also CEO of parent company TerraCycle. The worries surrounding reusability that have arisen amidst the COVID-19 pandemic haven’t seemed to apply to Loop, said Szaky, though they have been experiencing similar supply chain backups as other food and beverage companies. Though the nationwide online launch with Walgreens and Kroger was already in the works, it’s actually been accelerated to early this summer as more consumers have shifted to purchasing products online. “It’s not that single use is safe or unsafe, it’s not like reusable is safe or unsafe, it’s how you deploy those ideas that makes it safe or unsafe,” he said. “It’s the systems behind it that govern safety.” TerraCycle’s larger mission is to “eliminate the idea of waste,” said Szaky, through collecting and recycling materials that are not traditionally recyclable, like toothbrushes and candy wrappers, and also integrating waste back into products, like using ocean plastic in a Head & Shoulders bottle. With Loop, Szaky has taken the goal of waste elimination one step further, starting a division that “tries to solve waste without it ever occurring.” The root cause of waste is using things once, but single-use packaging hasn’t always been the norm, said Szaky, with milk bottles delivered by a milkman being a prime example. In fact, it only rose to prominence in the mid-1900s as packaging moved from being the property of the manufacturer to property of the consumer. “Do you want to own a coffee cup when there’s no coffee in it, or own a toothpaste tube when there’s no toothpaste in it?” said Szaky. “Why should we?” Owning the packaging comes at the price of the consumer, and as packaging is made cheaper, it’s usually made less recyclable. To address this problem, Loop partners with CPG companies to create reusable versions of their products that lower their carbon footprint, in a concept that Szaky said is “sort of like the idea of organic but instead of caring about farming practices, we care about reusability.” According to Szaky, brands are motivated to join Loop for two reasons: they get to innovate in ways they never have before, and they’re able to upgrade their sustainability. Once brands partner with Loop (and pay an onboarding fee), the company works with them to support the creation of sustainable packaging, like stainless steel ice cream containers and glass jars for beverages and nut butter. “Loop provides a much-needed innovation platform, challenging companies to take a fresh look at our value chains and integrate reusable product packaging as part of our efforts to waste-reduction,” said Laurent Freixe, Nestlé CEO for Zone Americas, in a press statement. “Nestlé is proud to be a founding investor and partner of Loop with the debut in the U.S of the Häagen-Dazs reusable container. It’s a critical part of our commitment to work with consumers to protect our planet for future generations.” Because new product development takes time, it can take from one to two years from the time brands sign on to the platform to actually begin shipping product to consumers. Szaky said of the 400 brands that have signed on, about 100 are currently shipping within the Loop system and the rest are in various stages of development. Partners like PepsiCo’s Tropicana orange juice, Purely Elizabeth granola, oatmeal and bars, Canadian brand Greenhouse’s kombucha and Nestle’s Chameleon Cold Brew are still in development. Retailers like Walgreens and Kroger are first launching Loop stores digitally, offering a selection of Loop products on their respective websites, before brick-and-mortar rollouts this fall where Loop will have its own section in the stores. Loop will also be rolling out in the United Kingdom, Canada, Germany and Japan. The company has also created its own private label brand, Puretto, to test consumer interest. Puretto items, which include products like cheddar crackers, pretzels and bagel chips, are usually sold for six to 12 months, long enough to show proof of concept, and indicate that a national brand is considering developing a product for the category. While individual companies, not Loop, ultimately set the price for items, Szaky said prices are typically kept close to that of the original product. In a time when certain products like baking ingredients or cleaning wipes are seeing online surges, there hasn’t been a push for one particular item on Loop. According to Szaky, products typically don’t perform “better or worse” on the platform. “If you buy a certain ecosystem of products and you like the idea of reusable, you’re buying that same ecosystem of products, but now in reusable,” he said.