The project started in September 2022, and after 18 months, it is the opportunity to look back over the work performed so far towards the development and deployment of reusable plastic packaging.
First, the consortium focused on the specifications for reusable plastic packaging. Industrial partners Vytal, Asevi, Ausolan, Dawn Meats, Uzaje, and Smurfit Kappa described their needs, and technical centers, IPC, AIMPLAS and CTCPA, university, TUS and industry Knauf Industries, translated them into technical specifications.
With all these elements in mind, the technical centers studied the bibliography and current market to select materials suitable for RPP. First prototypes were produced, with joint objectives of characterising an array of promising materials, while trying out a first ageing protocol. The results enabled the identification of a shortlist of materials, fit for each use case.
ECHO designs came up with their first design guidelines for first prototypes, and in February 2024, with the design freeze of five new packaging for the project. Now the consortium is working towards the realisation of those packaging by finalising the moulds required to produce them in series, for upcoming large-scale demonstrations.
Regarding quality and safety of RPP, the CTCPA, LNE and IPC implemented an accelerated aging protocol and several methods for assessing RPP performance and safety. A first design of decontamination equipment was achieved by Eternity Systems and Christeyns. The overall migration of existing RPP was assessed by the LNE, which also set up a washing protocol for microplastics collection and analyses. Finally, Eternity System set up a washing pilot line, dedicated to reusable packaging, which will be used during the large-scale demonstration phases.
In parallel, the University of Sheffield gathered data for social studies, focusing on six topics around RPP :
- consumer engagement with reuse systems,
- identifying social and behavioural issues with respect to reuse systems for household products,
- cross-cultural study of reuse for lunch on-the-go,
- effect of information about cleaning on concerns about contamination in reuse systems for takeaway food,
- study of users’ views of reusable packaging for raw meat in catering kitchens,
- effect of penalties and incentives on engagement with reuse systems.
The economical aspect of RPP was also studied, by Searious Business, with Cost-Benefit Analysis, identification of the profitability drivers, of the Value Chains of each use case, and identification of sustainable business models. Number of cycles (per container) and share of business (single use vs reusables) were defined as Key Performance Indicators for each use case, to be able to compare the success of the upcoming large-scale demonstrations.
Last but not least, IPC and the University of Sheffield worked on the overall assessment of all use cases. Methodological standards were chosen, as well as referential choice for Life Cycle Analysis (LCA), Life Cycle Costing Analysis (LCCA), Social Life Cycle Analysis (SLCA). Screening studies for LCA and LCCA were achieved for 5 use cases. These studies indicate a good environmental and economic performance when RPP is reused enough, often for around 20 reuse cycles, depending on the system studied. Finally, the partners defined the indicators and data collection strategy for an upcoming Social Impact Assessment.
