- 85% of milk in the USA is packaged in plastic jugs, so reducing the amount of plastic used can significantly lower the carbon footprint. - The presentation discusses studies on reducing plastic in milk jugs through lighter container designs, adding calcium carbonate filler, and optimizing both light-weighting and filler additions. - Integrated design across the supply chain, using minimum inputs and maximizing material use and recycling, is needed to create the most sustainable gallon jug in the future.

1. Creating A More Sustainable Gallon Jug
For Milk
Dr Gail Barnes, Partner, Personify LLC
International Dairy Show
Monday, November 4, 2013 - 12:30PM - 12:50PM
Booth 1074 - iDairyShow Theater
Chicago, IL

2. Summary
• 85% of fluid milk in the USA is packaged in monolayer HDPE packaging,
with the result that any reduction in the amount of plastic used can have a
major impact on reducing the carbon footprint.
• This presentation will discuss the results of studies of a progression of
ways in which the amount of plastic used in the creation of gallon jugs can
be reduced.
– Light-weighting through container design.
– Adding calcium carbonate as a filler.
– Light-Weighting + optimizing for calcium carbonate filler.
• These results meet recommendations coming out of the Life Cycle Analysis
study conducted by the Innovation Center for US Dairy which
recommended light-weighting or container weight reduction as a key
focus area for improvement in the supply chain impact of fluid milk.
• A recipe for the gallon jug of the future will be presented, and the
hypothesis made that “Integrated Design” will be the next frontier in
creating a more sustainable gallon jug for milk.

3. Packaging Principles
• Packaging should:
– Be fit for purpose.
– Be the lightest weight
possible.
– Use materials from the
most sustainable sources.
– Maximize opportunities for
recovery and recycling.
– Be designed to have the
lowest carbon impact.
– Be aesthetically pleasing
and convenient to use.

4. U.S. Fluid Milk Infographic
Source: Principles of a measurement framework: application to processing and
packaging technologies. Institute of Food Technologists
Annual Meeting and Food Expo, Las Vegas, NV, June 27, 2012

5. U.S. Fluid Milk Carbon Footprint

6. Processing & Packaging LCA
• Comprehensive LCA of fluid milk delivery
systems in the U.S.
• Assessment of environmental impacts of
18 fluid milk packaging and delivery
options.
Source: Principles of a measurement framework: application to processing and
packaging technologies. Institute of Food Technologists Annual Meeting
and Food Expo, Las Vegas, NV, June 27, 2012

7. Fluid Milk Delivery Systems Studied
Source: Principles of a measurement framework: application to processing and
packaging technologies. Institute of Food Technologists Annual Meeting
and Food Expo, Las Vegas, NV, June 27, 2012

8. Climate Change Impact Assessment
Source: Principles of a measurement framework: application to processing and
packaging technologies. Institute of Food Technologists
Annual Meeting and Food Expo, Las Vegas, NV, June 27, 2012

9. Non-Renewable Fossil Energy Assessment
Source: Principles of a measurement framework: application to processing and
packaging technologies. Institute of Food Technologists
Annual Meeting and Food Expo, Las Vegas, NV, June 27, 2012

10. Processing & Packaging LCA
Conclusion
• Differences between systems are relatively
small.
• Comparative assertions of performance are
not supported.
• Differences between systems are largely
defined by container material and mass.
Source: Comprehensive life cycle assessment of fluid milk delivery
systems, 8th International Conference on Life Cycle Assessment
in the Agri-Food sector, Saint-Malo, France, Oct. 1-4, 2012

11. Recommendations For Improvement
In Supply Chain Impact
• Container
– Container weight reduction, especially in on-the-go systems.
– Improved use of distribution packaging that can be used many times.
– Reduce energy use which improves multiple impact category effects.
• Processing plant
– Energy efficiency would directly lower impact to climate change and
costs.
– Water use and wastewater reduction in processing plant which will
affect eutrophication mitigation, and cost reduction.
– Avoid sewage overload which is the main contributor to nitrogen
emission to water and cause of eutrophication.
– Evaluate wastewater treatment discharges for potential reduction in
human toxicity, and eco toxicity, cost savings.
– Optimize out-of-date (from distribution and retail center) milk return
and use as feed.
Source: Principles of a measurement framework: application to processing and
packaging technologies. Institute of Food Technologists
Annual Meeting and Food Expo, Las Vegas, NV, June 27, 2012

12. Study 1: Light-Weighting Through
Container Design
12% weight savings through optimized
design alone
Source: Uniloy

13. Study 2: Adding Calcium Carbonate As A Filler
• Recycling recovery rate of 99% with CaCO3 levels
up to 8%.
• CaCO3 compounded in a master batch, doesn't
require changes to equipment except for the
addition of a material blender.
Source: Uniloy and Omya

14. Study 3: Light-Weighting + Optimizing
For Calcium Carbonate Filler
• Required optimizing
design to regain top
load e.g.
– Tucked in handle.
– Ribs on bottom and
shoulder.
• 54g bottle possible.
Source: Uniloy

15. Future Possibilities – Adding Recycled
Content
• Arla UK’s bottles already
made of 15% rHDPE.
• Bottles made with 50%
post-consumer recycled
content will be produced
at Arla's new Aylesbury
dairy.
Source: Arla Foods, Plastics Today

16. Future Possibilities – Using Bio-Resins
• Bio-plastics are plastics
made using ethanol
from renewable
resources such as
sugarcane and corn or
crop waste.
• Any grade of HDPE or
LDPE can be made using
the biopolymer.
• Up to 30% bio-resin
content envisaged.

17. Recipe For Tomorrow’s Gallon Jug?
• For a 56g gallon
jug:
– 29.7g virgin HDPE
reduces the
amount of virgin
HDPE by more
than 50%!
– 16.8 grams
biopolymer.
– 5.6 grams rHDPE.
– 3.9 grams calcium
carbonate.
Today’s gallon jug

18. “Integrated Design” Is The Next
Frontier
• Using the minimum input and getting maximum
use of materials at the end.
• Can only come about by the value chain working
together:
– Raw materials suppliers.
– Equipment manufacturers, e.g. of blow molding
equipment.
– Distribution equipment manufacturers, e.g. of crate
packing equipment.
– Processors/brand owners.
– Retailers.

19. Thank You
www.linkedin.com/in/gailbarnes
@DrGailB