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Sustainability and Plastics: Innovation at Dow Performance Plastics Drives Sustainable Solutions Bob Maughon Global R&D Director Performance Plastics and Feedstocks The Dow Chemical Company
Sustainability is Unsustainable?
2
http://imgs.xkcd.com/comics/sustainable.png
2
Metaphor for Sustainability
3
How about this one?
Is this Cup Sustainable?
4
Sustainablity is not an intrinsic property of a material. You cannot know by just looking.
Which is More Sustainable?
Plastic
5
Paper
Which is More Sustainable?
10 hours
6
1 mile
Financial Approach to Looking at Benefits
7
Why Not the Same Approach for Sustainability?
8
9
Sustainability Impact
Sustainability Impact Material
per Capita Consumption
(lb/yr) PET Packaging 17
Petroleum 6619
Natural gas 8037
Coal 6439
Gasoline 2495
Sand and Gravel 13923
Cement 512 Iron ore 340 Salt 403
Beef 54.3
Chicken 55.7
OO
O
O
O
OO
O
OO
PET
data from HIS, 2012 ERS USDA, 2011 National Mining Assoc., World Bank
30%
100% renewable PET (not yet
available) would required ~80 2 L bottles to offset
burning 1 gallon of gasoline or about
400 at todays 30%
10
Impact of Food Waste on GHG Emissions
11
P E R
F O
R M A
N C E
M A
T E R
I A L
S D
I V I S
I O N
Meat: Product vs. Packaging
Source: Table for One The Energy Cost to Feed One Person, INCPEN
Food Supply62%
Packaging5%
Transportation& Retailing
5%
Home Storage
14%
Home Cooking
14%
104 MJ / person / week energy used to produce and deliver meat and meat products (UK)
5% for primary and secondary packaging (all materials)
Packaging is All Types
12
P E R
F O
R M A
N C E
M A
T E R
I A L
S D
I V I S
I O N
Adding Packaging Can Actually Reduce Waste
| Global Sustainability
Source: Ron Cotterman presentation: How Packaging Prevents Waste and Enhances Sustainability, 2011
21 g of packaging protects 3.6 kg of meat.
Bone punctures caused rework and packaging failures. 70% of bone punctures occurred during retail display.
Addition of 25% more packaging (a small patch) reduced damage during retail display by 73%.
Result was a net reduction in total carbon footprint across the supply chain of nearly 6%.
Per 1,000 packages
13
14
Food Packaging Impact for Chicken
40 kWh/kg
~22% wasted
Pimentel and Pimentel, 2003
FAO, 2012
15
Flexible Packaging Helps Increase Shelf Life
Source: INCPEN
Plastic Packaging vs Alternatives
16
Packaging Conversion to a Stand-up Pouch
Package Type Contents
Impact per 100 oz Cereal
Landfill Discard
s* (g)
Process GHG**
(kg CO2 Eq)
Total Energy**
(MJ)
Paperboard and HDPE Liner
11 oz 380.0 .861 12.1
Stand-Up Pouch 12 oz 117.5 .265 9.25
Reduction vs Box
Landfill Discards 68%
GHG 69% Energy 23%
17
Rigid to Flexible Packaging Conversions
Reduction vs Rigid Packaging Alternative
Landfill Discards 50%
Plastic Used 60%
GHG 70%
Energy 50%
18
See more details at: http://www.kraftyespack.com/full/sustainability.aspx#
PE Strong Geographic Market Growth
0
2
4 6
8
10 12
14 16
18
20 22
24
26 28
30
32 34
36
38 40
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000
India Africa
SE Asia
China ME
Japan
W. Eur
NAA
11.2 kg per person
2012
P
E D
eman
d pe
r C
apit
a
(kg
per
pers
on)
Population (mill ions)
4.5 kg per person India, Africa & SE Asia
32.6 kg per person US/Can & W. Europe
2000
2005
2000
2005 2000 2005
2010
2010 2010
LAA E. Eur
19
Global PE Consumption Per Capita
Source: Dow, IHS
Global trends support continued growth for packaging Opportunity to differentiate and enhance consumer benefits with plastic
packaging Flexible plastic packaging provides functionality and an excellent
sustainability position
2012 Global Packaging Market ($698B)
Source: Vision Gain Market Research
0%
1%
2%
3%
4%
5%
6%
Rigid Plastic Packaging
Flexible Plastic Packaging
Flexible Foil Packaging
Flexible Paper Packaging
Board Metal & Glass
Growth Forecasts for Packaging Materials, 2011-2016
3.3% Projected Global GDP
Plastic Packaging Is Rapidly Growing
Source: PIRA-2011 figures shown with AAGR
Packaging Market Trends
20
Transportation
Dow Performance Plastics Competitive Advantage
21
Brand Recognition for High Performance from Differentiated Technology: LLDPE, HDPE, LDPE, Elastomers, EVA, Acrylic Binders, Adhesives,
Barrier Films, Fibers, Sealants, Tie Layers, Formulated Products
Packaging Hygiene & Medical
Consumer Durables
Infrastructure & Construction
Advantaged Business Model
Growth Markets Value Technology-driven Solutions
Strategic Advantage
Industry Leading Brands
Strong Technology
Portfolio
Attractive Markets
Broad portfolio of resin
technologies that enhance
packaging functionality and
deliver sustainability
benefits
Secondary and Tertiary
Packaging Adhesives Flexible Food Packaging
Rigid Packaging
Resin technologies for improved performance
and light-weighting
(Stretch Film, Shrink Film,
Stretch Hood)
Growth portfolio of innovative
packaging and laminating adhesives
Resin technologies that enable
light-weighting without
compromising organoleptics
(Caps & Closures, Food
& Beverage Applications)
Dow Focused Across Packaging Applications
22
P E R
F O
R M A
N C E
M A
T E R
I A L
S D
I V I S
I O N
The Plastic Packaging Lifecycle
23
Resources or
Footprint
Performance or
Value
Dow Performance Plastics Sustainability Focus
24
Improving our production footprint
Replacing alternatives with larger footprints
Developing new materials with enhanced performance
Enabling recycling opportunities
Providing advantages in use for customers / consumers
Catalysis Improves Process Sustainability
Increasing Thermal Stability and Efficiency
Polyethylene: Higher Efficiency and Plant Throughput Through Improved Catalyst Design
25
Downgauging Enabled for HDSS and Stretch Film
Industrial Sacks Pallet Stretch Film 26
27
Enhanced Stretch Film Performance
Conventional Film (23)
Dow Solution (12)
Real Case after 16 hours Lean testing
FILM Conventional
Downgauged Dow solution 20% thickness reduction = 25% more product packaged with the same amount of film
28
High Performance Collation Shrink Films
29
High Performance Polyethylene Sealants
Dow Foamed Film Solutions
DOW RESTRICTED 30
Polyethylene Stand-up Pouch
31
32
PacXPERT Flexible Packaging Solution
Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow
Designing Resins to Meet Customer Needs
Molecular Design What Our Customers Want
Average Molecular
Weight
Molecular Weight
Distribution
Density
Short Chain Branching
Distribution
Long Chain Branching
Resins that are:
Lighter
Faster
Cleaner
Aesthetically Appealing
Delivers Functionality
(Barrier, Reclose,
Scavenging)
What We Control
Monomer / Chemistry Used
Process Technology
Catalyst Used
Reactor Conditions
Comonomer
Additives
33
Key Capabilities from Discovery to Development
Proven Discovery, Development and Implementation
Drive Speed to Market
Scale Up and Development
Discovery High Throughput Research
Pilot Plant Capability
Global Technology Implementation
Design the Polymer Molecule
Product Prototyping Commercial Scale Testing
34
Computer modeling
Blown Film:
7 layer coex line
5 layer coex line
2 x mono lines
Adhesive Lamination
Sensory Science Lab
Analytical Capabilities
Physical Testing Lab
Vertical Form/Fill/Seal (VFFS)
Packaging Innovation Centers (Pack Studios)
Multivac Horizontal Form/Fill/Seal (HFFS)
35
Value Chain Collaboration on Packaging Design
36
Development Commercialization
Material Science
Process Research
Catalyst Research
Application Development
Research Development Commercialization
Market Driven Innovation Model
Global Customer Centers
Shanghai Freeport Horgen Jundiai
Converter
Supplier/Equipment Manufacturer
Brand Owner
Retailer
An average of 40 new products are launched globally each quarter driven by innovations in packaging
37
A Proven Track Record of Innovation
40s-50s 60s-70s 90s 2000s 80s 10s
2014
38 Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow
Investments Enable Accelerated Global Growth
39
USGC Investments
Performance Packaging Markets
1535 kta
Sadara Performance Packaging and
Performance Materials Markets 1300 kta
Creating the Foundation for Global Growth for Years to Come
Investment Startup
St. Charles Ethylene Restart 2012
Louisiana Ethane Flexibility 2015
PDH Propylene 2015
USGC Ethylene & Performance Plastics Units 2017
Sadara 2015-2016
Reduces material use 2 lbs of plastic deliver the same amount of liquid as 3 lbs of aluminum, 8 lbs of steel, or 27 lbs of glass.
Saves energy One truck of empty flexible packaging replaces 25 trucks carrying cans for the same amount of food.
Reduces emissions Organic waste in landfills emits methane: a GHG with 23 times more global warming potential than CO2 and plastic packaging helps keep food out of the landfill.
Saves resources By preventing food from spoiling and protecting consumer goods from damage during distribution.
Reusable resource Can be recycled to polymer or for energy at the end of its initial life.
The Benefits of Plastic Packaging
40
Thank You
Sustainability and Plastics:Innovation at Dow Performance Plastics Drives Sustainable SolutionsBob MaughonGlobal R&D DirectorPerformance Plastics and FeedstocksThe Dow Chemical CompanySustainability is Unsustainable?Metaphor for SustainabilityIs this Cup Sustainable?Which is More Sustainable?Which is More Sustainable?Financial Approach to Looking at BenefitsWhy Not the Same Approach for Sustainability?Slide Number 9Sustainability ImpactImpact of Food Waste on GHG EmissionsMeat: Product vs. PackagingAdding Packaging Can Actually Reduce WasteSlide Number 14Flexible Packaging Helps Increase Shelf LifePlastic Packaging vs Alternatives Packaging Conversion to a Stand-up PouchRigid to Flexible Packaging ConversionsSlide Number 19Packaging Market TrendsSlide Number 21Dow Focused Across Packaging ApplicationsThe Plastic Packaging LifecycleDow Performance Plastics Sustainability FocusCatalysis Improves Process SustainabilityDowngauging Enabled for HDSS and Stretch FilmEnhanced Stretch Film Performance Slide Number 28High Performance Polyethylene Sealants Dow Foamed Film SolutionsPolyethylene Stand-up PouchPacXPERT Flexible Packaging SolutionDesigning Resins to Meet Customer NeedsKey Capabilities from Discovery to DevelopmentPackaging Innovation Centers (Pack Studios)Value Chain Collaboration on Packaging DesignMarket Driven Innovation ModelA Proven Track Record of InnovationInvestments Enable Accelerated Global GrowthThe Benefits of Plastic PackagingSlide Number 41