Applying circular economy principles from the onset to product design and packaging may deliver a competitive edge rather than added complexity. Here at Philips, we have been redesigning our packaging over the years and these are our key takeaways.
1. Define circularity at the design stage to optimize materials
The first step for circular packaging is to identify the packaging design based on the model that best fits the application. If packaging shall be recycled, it shall be made of recyclable materials. If it is reused, it shall be designed on durability.
When it is identified that the packaging will end up in a recycling system, design it so it can be recycled, by for instance having no Polyvinyl chloride (PVC) or Expandable Polystyrene (EPS). If you know it will be returned, then ensure that packaging can withstand several return cycles. These kind of designs will resolve any potential conflict between material optimization and end-of-life requirements.
After observing the pattern of logistics of sending X-Ray tubes, at Philips we created a robust and reusable transport box to carry new tubes to customer sites. These transport boxes function twice; firstly, to bring the new tubes and secondly, as a return box for the old tubes that will be sent back to the production facilities for refurbishment. The circular loops are closed for both the packaging itself through reuse and for the product through servicing.
Next to this for many of our factories we use returnable packaging in the supply chain too. We use crates instead of cardboard boxes for delivery of parts from the supplier to the factory. As these creates are reused multiple times, we have managed to reduce large amounts of packaging waste.
2. Work with packaging suppliers to scale up this innovation
Last year we have published a new sustainable materials policy to guide us in implementing sustainability efforts in all product categories. The policy focusses on several topics including the use of recycled materials for both cardboard and plastics, sustainable sourcing of wood materials in case recycled materials are not available and the use of bio-based materials.
Besides the strong focus on using recycled materials in packaging, Philips also want to use materials that are easy to recycle or come from renewable sources. Through our Philips Restricted Substances List we restrict the use of PVC and Expanded polystyrene (EPS) and other polymeric foam materials as these materials cannot be properly recycled when disposed. EPS is only used in heavy consumer products where we cannot reach the right level of protection with cardboard buffers. We aim to reach the highest level of recycled content while maintaining a great look and feel of the packaging material.
3. Identify how customers use and see packaging
We know that packaging is a big concern for our customers, namely hospitals. As part of their environmental management, hospitals want to have as little packaging as possible, want it to be recyclable and it must not contain hazardous substances; and for that Philips offers hospitals take-back & recycling schemes.
Next to this, we also expect the consumers of our household appliances to focus even more on recycling materials in the future. Philips aims to make packaging that contains more recycled materials, is easier to recycle and has clear return instructions.
Our revolutionary high-end steam generator PerfectCare Elite is a great example for advanced and sustainable packaging: 100% recycled carton and no use of EPS which is harmful to the environment and not ideal to be recycled. A complex jigsaw structure of carton protects the rather heavy appliance in a drop test from more than a meter height making sure our consumers always receive a 100% new and undamaged product. Due to the superior quality of the carton used, no additional protecting brown box is needed and several boxes can easily be stapled on each other optimizing space in containers, all leading to a significantly lower CO2 footprint.
The ‘pizza box’ model packaging or what is called retention packaging is used for spare parts shipment between the spare parts warehouse and the customer. Once a service engineer installs the new spare part at the customers’ location, this packaging is used to bring the old part back to the warehouse. Photograph: Phillps
This image shows how components are transported from our suppliers to the assembly lines. In the past cardboard boxes were used, now we use returnable packaging. Photograph: Philips
This product - the steam generator perfect care elite - is completely packed in cardboard so we don’t use any EPS as a buffer. By folding the cardboard in several angels we manage to create a buffer strong enough to withstand a drop test. This is really heavy product so it is quite an achievement. Photograph: Philips
The packaging for this product is made from 90% recycled cardboard and 50% recycled plastics. Photograph: Philips
Content on this page is paid for and provided by Philips, sponsor of the circular economy hub
