Durable Plastic Wrap for Big Rugs
thesambak
Hello Greener Package!
I am looking for a sustainable packaging solution for large rugs. The rugs in question are generally 5x8 in size and ship standing vertically. Currently, they are wrapped in a #4 HDPE that is approximately 30 inches wide. This provides just enough support to keep the rugs vertical during shipping and on the shelf. There is also a label that is slid under the plastic wrap and is visible to consumers. Clarity is key.
SO here is our debate.
-We want to use a material that is strong, will not tear, and will continue to provide the function that the current solution provides.
-We have considered moving to a higher content recycled #4 HDPE. Moving from 0% to 25% recycled content.
-We have considered looking at #2 LDPE as an alternative but cannot find an appropriate material that performs in the same manner. (This is also preferred as a consumer could recycle the plastic in most community recycling programs. We found many do not accept #4)
-We have considered looking at bio-based packaging materials, yet find the lifecycle impacts to be significant as most are derived from corn.
-We have explored not using plastic at all, yet have been unable to find a solution that performs the same way on the shelf and in transit.
So, I pose the question to you great packaging minds. How can I get a rug to stand vertical, display a label, and be made of a material that is minimal in its impact on the environment?
As my first post, I welcome your feedback.
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Durable clear rug wrap
Timothy Bohrer
It seems to me that you have already largely answered your question. Given the need for clarity, you are talking about using a clear film, so long as you want to completely contain the rugs and are not interested in exposing them to dirt contamination through the use of a drawn up netting of some kind. Given the weight of the product and a difficult transportation cycle, you need a tough package that displays a fresh looking package and product at retail.
In films, you have chosen a commodity material, HDPE, that is tough, scuff resistant and rigid, which seems like a good combination for your needs. A reasonable stream of recycled HDPE material is available, and you could check out the performance and cost of film substituting some recycled content for virgin. I assume you have explored how thin an HDPE film satisfies your needs and you have moved to that, possibly gaining some weight reduction.
There may be some internal confusion on the codes for recyclability; HDPE is #2 and LDPE is #4, and you should appropriately see more post consumer collection acceptance for HDPE as a result. Many of the plastic 'T-shirt" bags, particularly at grocery stores, are HDPE and consumers could drop off the rug wrap at collection points for those shopping bags.
While the bio materials are improving rapidly, in addition to you wondering about the impact of the diversion of resources from food, the biggest issue you should be focusing on is adequately protecting and merchandizing your product. The first criteria has to be to meet the technical needs of the packaging challenge.
It is very important to remember that the worst environmental impact of a package is to fail to protect a product adequately. A product that is wasted before the consumer can use it is a true environmental disaster.
It is possible to over-think these things, especially when a simple and effective solution is already in place. You seem to be in a good place, with the potential to add some recycled content; on a weight basis, your package to product ratio is small and with proper labeling you should be able to lead your consumers to a convenient recycling stream for their used packaging.
If you can give on some implied, but unstated constraints, such as dirt protection mentioned above, you might open more options, but without being clear about what tradeoffs you are willing to accept, it is not so easy to create an obviously superior solution.
Boxes for rugs
Modern Rugs...How about using recycled cardboard boxes to ship the rugs. We often use this means for larger rugs because usually they need more support and better protection on account of their weight as opposed to smaller lighter rugs. It is quite costly to have these purposly made so somewhere along the line you will have to factor this into your costs.
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