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Client : Hydroserre

In market : 2017

Objectives of the initiative

Responsible agriculture is at the heart of each of Hydroserre’s decisions. Our various greenhouse crops, hydroponic and organic, apply the principles of sustainable agriculture that are respectful of the environment. We avoid overexploiting the land, systematically using pesticides, and favour the recycling of water as well as green and renewable energy. This environmentally friendly approach extends all the way to the choice of packaging.

We strive to provide our customers with products that are responsible from the beginning to the end of their lifecycle. So, why wrap lettuce in plastic? To avoid food waste. Storing a head of hydroponic lettuce in a dome extends its life by 14 days as it reproduces a mini-greenhouse environment and maintains the level of humidity required to preserve the lettuce’s freshness! Hydroponic lettuce is much more sensitive than field-grown lettuce, which is why they protect it with packaging that mimics small-scale greenhouse conditions. Indeed, without the effects of rain, wind and pests or the exposure to herbicides and fungicides, hydroponic lettuce is much less fibrous and therefore, more sensitive to handling.

In addition to focusing on reducing food waste, we wanted to further develop our approach on our impact on the environment.

We therefore started an ecodesign initiative regarding the packaging for our Boston Premium lettuce. From the start, our goals were to develop packaging that generates less greenhouse gas (GHG) emissions over its lifecycle, is recyclable and optimal in terms of palletization and boxing. These improvements have made it possible to cut our GHG emissions by 16%.

Challenges

Our biggest challenge is the demonization of plastics. It puts us in a difficult position, because just like our consumers, we do not want our packaging to end up in the oceans at the end of its lifecycle. However, market intelligence reveals that alternative materials to plastic that offer good moisture barrier properties are very limited in the food industry. When our polyethylene terephthalate (PET) domes are placed in the recycling bin, they end up in material recovery facilities, where they are sorted with other PET containers and packaging. The resulting PET bales are sold to processors or recyclers who will granulate it, wash it and put it through the plastics extrusion process it to give it a second life.

Another challenge in designing the "right" packaging has been finding the right balance to have adequate thickness of the plastic while maintaining the quality and preservation of the product on shelves. Several tests were necessary to determine the best compromise.

Finally, improving our consumer communication strategy was also a challenge. It is important for us to show our commitment and desire to reduce our environmental footprint, and to back that up through our actions. We are listening to experts and always on the lookout for changes in the supply of eco-responsible materials.

Benefits

Our first goal was to develop packaging that generates less greenhouse gas (GHG) emissions over its lifecycle and to avoid over-packaging. The quantity of material used and the headspace of our old packaging have been significantly reduced. As a result, our packaging-to-product weight ratio has been cut by 14%.

Our second objective was to select the material with the highest recyclability potential in Quebec. Because we recognize the bad press that plastics get, we consulted with experts to assess other material options for social acceptability, including compostable plastic. Our choice ultimately turned to PET as being one of the most widely locally recycled plastics in Quebec. We chose a resin made from recycled plastic. In order to align even more with best practices for recyclability, we are now focusing on improvements that can be made to the label.

Our third objective was to optimize the packaging for better boxing and palletizing in order to maximize the quantity of products being shipped with each run. That optimization has made it possible to increase the number of products that can be transported per pallet by 17 % and reduce the number of containers used to ship one tonne of products by 17 %.

Optimization actions taken

We have used virgin PET since 2016, but are currently transitioning our packaging to post-consumer recycled plastic PET. Our Fleur de Mirabel product is made of 100% post-consumer recycled plastic.

  • Extend the product’s life
  • Improveme the product’s handling
  • Fewer product loss during use
  • E-mails
  • Employee meetings
  • Communicating with suppliers
  • Direct consultation with their suppliers
  • With a consultant
  • Direct consultation with our suppliers
  • With a consultant
  • Identification of plastic resins using SPI codes (e.g.: 1 for PET, 2 for HDPE, etc.)
  • Appropriate logos (Möbius strip) are affixed
  • Communicate on the organisation’s website

After optimization

16% Reduction of greenhouse gas emissions

9% Increase in recycled materials content

14% Reduction of the packaging/product mass ratio

14% Decrease of the amount of materials used

17% Decrease of number of containers used to transport 1 tonne of products