Use Of Recyclable Packing Materials

MOCHIZUKI Masahiko¹ WADA Yasushi² KAKU Kunio³ TOSHIMA Takeaki¹

Environmentally improved packaging can increase customer satisfaction significantly. We have been striving to develop creative packaging and distribution methods that safeguard product quality while reducing the impact on the environment. We replaced approximately 50% (in gross weight) of packing cushions for measuring instruments from traditional styrene foam (expanded polystyrene) to a combination of easy-to-recycle pulp mold and film cushions made of 100% recycled material by the end of fiscal 1999. Also, we have been continuously improving the way of delivering products to our customers, such as developing and testing more effective shipping methods that use less packaging, maintain product quality, and result in less waste.

1. Dept. 1, Manufacturing Engineering Div., Servicing and Man- ufacturing Business Div.
2. Environmental Conservation Promotion Dept.
3. Development Dept., Manufacturing Engineering Div., Servicing and Manufacturing Business Div.

INTRODUCTION

Figure 1 Phased Reduction of Styrene Foam

Traditionally, Yokogawa has used styrene foam (expanded polystyrene) as cushioning materials to ensure that products are transported safely. Since different styrene foam cushions are required for different products and Yokogawa is a typical manufacturer producing small quantities of many models, we have had a vast stock of cushions of different shapes and sizes. However, as environmental issues have become a major concern for corporate management, such stock has become a problem in terms of resource preservation, recyclability, and disposability.

We therefore focused on electronic measuring instruments first since particularly large amounts of styrene foam were used for them among Yokogawa's products, and studied the feasibility of using pulp mold and film cushions. Various tests to assess the reliability showed the feasibility of such cushions. Figure 1 shows the plan and progress of phased replacement toward using packing materials of higher recyclability and reducing the types of materials. Regarding minimizing the amount of packing materials used, techniques for reusing packing materials by developing a packing material recovery system as well as a delivery method using returnable, reusable plastic containers are under study.

PULP MOLD CUSHIONS

Figure 2 Pulp Mold Cushions

Pulp molds are molded from liquefied waste paper and used as packing cushions. We use pulp mold cushions to pack products that weigh 5 kilograms (11 pounds) or less, that are manufactured in quantities of at least 300 per month, and that can withstand at least 588 m/s 2 (equivalent to a free fall from a height of 120 cm). This is because a pulp mold cushion may not be able to withstand the impact of a drop for a product heavier than 5 kilograms; and also because it is difficult to recoup the investment needed for producing the mold for a product of which fewer than 300 are manufactured per month.

Figure 2 shows the pulp mold cushions for the µ R1000 recorder, for example.

 

FILM CUSHIONS

Figure 3 shows an example of packing with film cushions. Film cushions are made of rugged, elastic, non-slip sheets of film adhered to a cardboard frame. The product is supported by two sheets of film that absorb shock, and floats in a package. Due to their flexibility, film cushions are widely used for computer- related devices in the United States and Japan including Hewlett- Packard products. Film cushions are suitable especially for products with fragile surfaces and can be used for a large number of products provided the film is appropriately elastic for the size and weight of the product (20 kilograms [44 pounds] or less). Table 1 shows the experimental data.

Table 1 Result of Assessment Test for Packing Material Properties

Drop Test
Condition	Item	Setting
Model		DX204
Mass of model		6.6 kg
Ambient conditions		Room temperature
Height of fall and method of dropping		90 cm high, free fall
Posture of drop		1 corner, 3 ridgelines, 6 faces
Impact acceleration applied to model (m/s2)		Max. 480
Impact active time for model (ms)		40
Overall evaluation		No problem observed
High Temperature and Humidity Test
Condition	Item	Setting
Model		DX204
Mass of model		6.6 kg
Ambient conditions		60 ° C, 95% RH
Test duration		36 hours
Result (warpage of frame)		Direction of longer length: 5 mm
		Direction of shorter length: 2 mm
Drop Test after High Temperature and Humidity Test
Condition	Item	Setting
Height of fall and method of dropping		90 cm high, free fall
Posture of drop		Bottom face
Impact acceleration applied to model (m/s2)		290
Impact active time for model (ms)		40
Overall evaluation		No problem observed

The greatest merit of film cushions is their versatility: the same film cushions can be used for different products that slightly differ in external shape and dimensions. Besides, the sheets of film can be easily pealed off from the cardboard to facilitate recycling of the cardboard and, above all, they can be incinerated at a low temperature since the film produces no toxic gases.

Film cushions offer superb workability for packing, unpacking, and segregated disposal including when the customers dispose of the packages by themselves. Although the cost of the film is high at present, the cost will decrease if the film becomes widely used as a mainstream cushioning material, thus allowing it to be used for more products of Yokogawa.

CONCLUSION

Figure 3 Film Cushions Used for Packing a DL1500 Digital Oscilloscope

Pulp mold and film cushions that have already been proven and used by Yokogawa are examples of easy-to-recycle packing materials. Nevertheless, to create a sustainable society it is critically important to reduce the total amount of packing materials. We must therefore devise a system to deliver products using plastic containers that can be reused repeatedly and recover the containers, and should create a delivery method that ideally uses almost no packing materials. And when packing materials must be used, the materials should be picked up and reused by the manufacturer, the same as for returnable plastic containers.

Improvement of packing materials has emerged as a crucial theme that must be tackled by many companies globally. Efforts to harmonize business development with ecological needs will surely result in the invention of new methods such as film cushions. But in addition to the packing materials, it is also important to design suitable products that are economic and environment-friendly.

We shall not be complacent with our success to date, but will continuously strive to reduce, reuse, and recycle packing materials while assuring quality and suppressing cost.