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Concentrated Laundry Detergents in Water Soluble Film for Home Care
An IHPCIA Initiative
1
November 30, 2018
Save Water Save Energy Save CO2 Save Packaging
Industry Vision–Harmony with Nature 2
An IHPCIA Initiative
Factors affecting Home Care Sector
•Lifestyle Changes
•Stressed environment •Multi Polar World
•Digital Technology
3
Plastics Pollution in Ocean & Solutions
• Plastics in the ocean contributed to 8 mn tons in 2012 and this has gone
upto 12.7mn tons in 2018
• Greenhouses gases have gone up by 17.5% during the same period of six
years.
What are the solutions?
Moving away from single use plastics and looking at the ban imposed on the
use of plastics the only option is to look at alternatives that can save water,
energy and efficiency
6
Sustainable Consumption and Production and the Role of Green Products in India
7
An IHPCIA Initiative
Changing Consumer Preferences
Consumers are now looking at value for the products that
comes through the design of the products. There is growing
emergence of preference for regional players 'products
In the multi polar world there are disruptive trends and hence
there are opportunities.
8
Living Differently
• I want what I want when I want it
• Growth by population and income is no more valid
• More people are preferring outsourcing of laundry
• Digital Technology Revolution – Smart homes of the future
• Consumers want personalised solutions and smart
production.
9
Smart Production
• With focus on concentrated liquids and out of foam
technology.
• Increased focus on biotechnology. Use of green surfactants –
plant based, sugar based and algae based.
10
Technology Innovations-Key to achieving cleaner products and sustainable growth
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Impact:
1. CO2 Imprints
2. Reduce Water Consumption
3. Reduce Energy
4. Biodegradability
Sustainability via the Bio
based economy and
Monodose
An IHPCIA Initiative
• Sustainability marketing strategies should aim towards improving the awareness of
• Consumers to use the product in an informed / sustainable way
• Existing Mechanisms such as Eco labels and safe use tips provided on the pack are confusing
consumers believe that there is insufficient or too much information provided
• Monodose is the sustainable option.
Actions needed (non technological) to improve the sustainability profile of the industry
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An IHPCIA Initiative
A Sustainable Solution Concentrated Laundry Detergent (CLD) in WSF
Product innovation has been one of the major influences in reducing the
environmental impact of laundry detergent. Sustainable consumption of
detergents has been promoted by linking it to other benefits which
consumers find more important. CLD in WSF can do that by:-
• Offering products that use natural ingredients derived from renewable sources
• Eliminating use of minerals, fillers, phosphates and zeolites
• Making products in concentrated form
• Use of water soluble films (polyvinyl alcohol)
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An IHPCIA Initiative
A Sustainable Solution Concentrated Laundry Detergent (CLD) in WSF –contd.
CLD products has seen enthusiastic response from customers in several markets
where it has been introduced so far and has garnered 17% market share in the US
in just five years thanks to its benefits of consumer convenience and precise
dosing.
The Indian market is ready to take on this novel product as several factors are in
favour: ban on multi-layer packaging; space constraints in urban homes; stressed
water availability; greater number of women in the workforce and hence demand
for more convenient products etc.
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An IHPCIA Initiative
Why CLD in Water Soluble Films (WSF)?
Precise dosing (no over- or under-dosing)
Consumer convenience (no measuring, easy to use)
Separation of ingredients via multi-
compartment designs
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An IHPCIA Initiative
Save The Planet!
Reduces Shipping Cost Lower Water Shipped Reduces use of plastic packaging Lower energy consumption Cold water wash 100% Biodegradable CO2 imprint significant
Bulk Detergents CLD-WSF
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An IHPCIA Initiative
Indian Scenario
• 15 thousand tons of detergent powders consume 15mn plastic
bags per day
• IHPCIA aim is to facilitate reduction of use of plastics @10%
per year with 2022 target of reaching 40% reduction of
plastics
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USA
France
UnitedKingdom
Japan
Spain
Canada
Italy
Belgium
Germany
Switzerland
Other
0
500
1,000
1,500
2,000
2,500
3,000
2014 2015 2016
Global Laundry Market
52% 51%Powder51%
7% 8%Std.liquid
9%
34%34%
Conc.liquid34%
6%7%
Unitdose7%
-
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
2014 2015 2016
Share by Category (Retail Value)
Unit Dose by Country (Retail Value)
5%
11%
12%
Unit: Mil USD
Unit: Mil USD
• Global SUD market rapidly growing: 21% CAGR (2012-2016) • Monodose market growing at 11% (vs. 5% for overall detergent) in 2016 • Potential for geographic expansion in India by leap of technology
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An IHPCIA Initiative
Indian Detergent Market Landscape
Current Market Size (Organized Detergent Market)- USD 2.21(Billions)
Total Volume (Production) : 2.5 Million Tones
CAGR(2012 -2016): 10% approx.
Washing Machine Penetration in India:9 %
Indian Population Division:
Urban: 33%
Rural : 67%
Households Owing Washing Machine:
Urban: 27.5% of all Urban households
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Comparison of Formulations Detergent Powders Vs CLD in WSF Pouch
Contents Detergent Powder Monodose
Popular (1kg) Premier (1kg) Liquid pouch
Dosage 100 gm Dosage 65 gm 25 ml/dose
Actives % 12 20 65
LABSA 12 LABSA 10 Naturals+
SLS/SLES 5
NI+PG +Enzymes+
Polymers 15
AOS/NI 5 Solvent
Fillers/Soda Ash % 60 20 NIL
Salt/Sulphate % 10 25 NIL
Talc/Bentonite % 5 NIL
Performance
Enhancers % NIL 10 2
Polymers % 1 3 1
Enzymes % nil 2 2
Moisture % 10 5 5
Packaging Poly bag Multi-layer bag PVA film
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An IHPCIA Initiative
What does CLD packed in WSF pouch do?
Laundry Detergent
CLD Automatic Dishwasher CLD
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An IHPCIA Initiative
Next Generation Films
POWDERS POWDERS (AG CHEM)
LIQUID LAUNDRY
MULTI-COMPARTMENT LIQUID LAUNDRY
CHILD SAFETY COMPLIANCE
1961 1991 1999 2012 2015 2018
Evolution enabled by Innovation
INNOVATION
• Low residue • High thermal formability
(Pouch design flexibility) • Added functionality • Enhanced compatibility • Enhanced machine
handling • New applications
(Personal care, etc)
An IHPCIA Initiative
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Evolution enabled by Innovation (Contd.)
• Bulk Sized Packs
• Machine Dispensers e.g. Cleanyst Dispensers
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Development of CLD in WSF in India
• Films Selection
• Formulation Development
• Equipment supplier
• Co-packer
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An IHPCIA Initiative
Detergent Formulation • High concentration • Single or multi chamber • Liquid / Powder
combination
Conversion Equipment • Line speed • Sealing method • Single/multi chamber • Cavity shape/design
Water Soluble Film • Dissolution • Chemical resistance • Physical properties • Compatibility testing
Coordinated
Product
Development
Developing CLD Products
PROCESS ABILITY
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An IHPCIA Initiative
PVOH Film Compatibility
Further hydrolysis of residual acetate (pH effect)
− Special film grades are required for formulations with high (alkaline) and low (acid) pH – above 8 and below 5.
Crosslinking
− Includes gelation (i.e. boron compounds)
− Esterification (i.e. polycarboxylic acids)
− Intermolecular dehydration
Formation of acetic acid from sodium acetate
Oxidation (eg., by Cl2)
Reverse salting out effect (by salts/ionic strength)
Inhibition of film solubility in salt solutions
Inhibition of film solubility when salts partially dissolve into film
Reactions on hydroxyl by reactive functional groups
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An IHPCIA Initiative
Ingredient Incompatibility
Chemical Examples
Water Maximum of 10 wt% free water recommended
Tri- and tetra- amine Diethylene triamine, and triethylene tetramine
Boron containing compounds Sodium perborate, borax
Inorganic and organic halogenated compounds Inorganic chlorine* compounds
Strong oxidizing agents including halogenated compounds
Persulfates, percarbonates (may be tolerated with limited moisture ingress)
Phosphates Sodium tripolyphosphate, tetrasodium
pyrophosphate
Di- and tri-carboxylic acids* Citric acid, oxalic acid, maleic acid
Dialdehydes* Glutaraldehyde, glyoxal
Monoaldehydes under acidic conditions* Often present in fragrances especially floral
Cupric salts Zinc, aluminum, titanium, vanadium, chomium
salts, or esters
Ionizing Soluble Salts (Inhibits solubility of PVOH film)
Sodium sulfate at approx 5 wt %
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An IHPCIA Initiative
Physical Compatibility: Plasticization of film and/or moisture loss causing embrittlement
Examples
All hygroscopic solids
Clays (bentonite, kaolin, etc), diatomaceous earth
Microporous Materials, Zeolites, aluminosilicates, aluminophosphates
Quaternary Ammonium Compounds
Examples
All hygroscopic liquids
Many organic solvents, especially aliphatic solvents and lower alcohols
Most glycols (glycerin, propylene glycol, diethylene glycol)
Max of 20 wt% recommended
Ethanolamines
• Solid Formulations
• Liquid Formulations
Ingredient Incompatibility 29
An IHPCIA Initiative
CLD example
Family Type Typical Range
Surfactants (Anionic, Cationic, non-ionic) diethanolamine, triethanolamine,
monoethanolamine, etc.
45-70 %
Base/Builder Oleic Acid 18-23 %
Solvents Propylene Glycol, Diethylene Glycol,
Glycerin, etc.
18-23%
Water - 3-10%
Fragrances Free + PMC 0.1-1.5%
Enzymes Amylase, Cellulase, Lipase, etc
0.2-0.5%
Optical Brightners, Sequestrants other 0.2-2%
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An IHPCIA Initiative
Water Soluble Film Converting Options
MonoSol has strong relationships with equipment manufacturers and contract packers to support water soluble film conversion. • Rotary Drum – PVA continuous motion drum technology is
used to form water soluble materials (polyvinyl alcohol) at speeds of up to 2400 packages per minute.
• Flat-bed intermittent line
• Vertical Fill Form Seal – VFFS • Pleat wrapping compressed tablets
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An IHPCIA Initiative
Rotary Drum
High speed, high capacity
Top-line
40 million pouches/year
Cost: $500k-1.2 MM
Options dictate cost: Powder, liquid, chambers, output
Additional costs: packing lines, environmental controls
Typical payback: 18 months
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An IHPCIA Initiative
Secondary Packaging
Require appropriate secondary / outer
package to keep moisture in and out.
Suggested options include stand up pouch &
injection molded or thermoformed
tubs/containers/jars using commonly
available polymers such as PP, HDPE, PET
etc.
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An IHPCIA Initiative
RDM Investment Model
INPUT
Machine Cost & Parameters: Film Inputs & Cost:
Select Machine Type RDM 165 Liquid Select Choose Film Type M8720 Select Choose Film Thickness Application -Powder / Liquid Liquid Top 3.0 Select Bottom 3.0 Select
Cost of Machine $ 470,000
Additional Machine Costs $ 80,000 Cost of Film per kg $ 18 Machine Running Hours (Daily) 16 Machine Run Days Per Month 24 Labor Cost: Packaging: # of Employees 6 Type of Secondary Packaging Standup Bag Select
Pay per Hour $ 1.00 Count per Finish Package 30
Formulation: Pouch Costs:
Formulation Type Liquid Price per Pouch $ 0.15
Estimated Cost of Formulation / Pod $ 0.06
Cost per Pouch $ 0.10
Selling Price: Selling price / finished pack $ 4.50
An IHPCIA Initiative
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OUTPUT
Running Cost Breakdown
% of Run Cost
Cost of Film $ 1,054,280 22%
Cost of Formulation $ 2,900,670 61%
Cost of secondary Packaging $ 241,723 5%
Cost of Conversion $ 569,849 12%
Machine Payback:
Investment Cost $550,000
Running Cost $4,766,522
Total Unit Output per Year 48,344,503
Total Finished Packages 1,611,483
Estimated Investment recovery time (months)
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Return on Investment
Total Revenue per Year $ 7,251,675
Total Running Cost per Year $ 4,766,522
Total Profit per Year $ 2,485,154 * Run Waste : Side trim included in calculation
An IHPCIA Initiative
35
Implementation
• Formulation development
• Design development
• Equipment acquisition and installation
• Film selection and supply establishment
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An IHPCIA Initiative
Timeline
Formulation and Film development/selection: 6-12 months if
new; lesser if current
Equipment: 6-8 months
Film supply: 2-4 months
Secondary packaging design and development: 3-6 months
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An IHPCIA Initiative
Safety Measures: CLD in Unit Dose
Aversive agent in film
Compressive strength of SUD > 300 N
SUD retains detergent liquid for ≥ 30 s in
water (20°C)
38
An IHPCIA Initiative
Safety Measures: Outer Packaging
Child-impeding re-closable closure
Needs coordinated
action of both hands
On-pack labeling using attention-grabbing icons
Opaque container
39
An IHPCIA Initiative
For this we have been working on different aspects throughout the process, either its related to changing structural parameters of packaging material or even if it is linked to upgrading packing machinery.
Initiatives Taken By RSPL In Plastics Reduction
40
Initiatives Taken For Reducing Plastic Consumption In Primary Packaging Material
UPGRADING PACKING MACHINES
By upgrading our finished goods packing machines we have been able to reduce packaging material wastage up to 5-6% of our total consumption which is approximately 150 MT. of packaging material saving per annum, and we are continuously working on it further to minimize it as much possible.
For bulk detergent pack we have introduced new style of packing, that helped us to reduce the packaging material wastage up to 3% - 4% which is approximately 30 MT. per annum and has been reduced to nil.
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• REDUCING PACKAGING MATERIAL THICKNESS We have worked on our packaging material quality that could help us to reduce plastic consumption, for which we took an initiative to reduce the thickness of the packaging material from 15 % to 25% without compromising with the packing quality. The overall outcome of this initiative was that we achieved to reduce our plastic consumption up to 2000 MT. per annum.
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REDUCING PACKAGING MATERIAL THICKNESS As similar to primary packaging material quality working the same concept was introduced for our secondary packaging material also and after working on the same we reduced the thickness of our secondary packaging material from 25 % to 30%, and this initiative helped us in achieving to reduce our plastic consumption up to 500 MT. per annum.
INITIATIVES TAKEN FOR REDUCING PLASTIC CONSUMPTION IN SECONDARY PACKAGING MATERIAL
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• Overall reduction in plastic consumption through primary packaging material is approximately 2180 MT per annum. • Overall reduction in plastic consumption through secondary packaging material is approximately 500 MT per annum. • As we are continuously working on further in the field and we have targeted to reduce packaging material & process wastage up to 1000 MT. to 1200 MT. in next 5 years with addition to the numbers that we have already achieved .
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THANK YOU
Mr. Sanjay Trivedi Director Indian Home & Personal Care Industry Association Tel: +91 22 2877 1857 Fax: +91 22 2874 1366 Email : [email protected] URL: www.ihpcia.org