Skip to main content

Client : Metro

In market : 2022

Objectives of the initiative

In keeping with our Packaging and Printed Materials Management Policy, the main objective of the ecodesign approach was to integrate more recycled content into the packaging of our Selection line of toilet paper products to improve the circularity of the plastic. The secondary objective was to achieve source reduction, specifically by reducing the packaging’s total mass.

In collaboration with our partners, we developed a new packaging prototype made of 100% recycled LDPE (low-density polyethylene) resin. The research and development for the toilet paper product packaging is rooted in seven guiding ecodesign principles that cover every stage in the packaging life cycle, from design to end-of-life:

  1. Informed decision making with respect to product design to limit the environmental footprint.
  2. Optimized design to maximize the use of raw materials, thus limiting resource consumption and eliminating overpackaging;
  3. Carefully considered material and inputs, prioritizing recycled content to manufacture the product and use of responsibly-sourced certified virgin fibers when necessary;
  4. Smaller footprint by operating production facilities to manufacture and market products that consume less water and energy and reduce greenhouse gas emissions;
  5. Mobilization of consumers and end-users by raising their awareness and educating them on ecodesign topics;
  6. Smart value chain by considering product efficiency across the supply chain and constantly seeking opportunities to design or use reusable packaging, specifically in e-commerce;
  7. Responsible end-of-life management by designing packaging to promote end-of-life recycling when it is the optimal channel to dispose of the product. When it is not, composting is an appropriate solution.

Challenges

Several challenges were encountered as we rolled out the initiative. Recycled plastic film does not mimic virgin film. Its physical properties are more variable and therefore create challenges for toilet paper packaging. In addition, friction coefficient issues which can cause friction on the converting line compelled us to fine-tune the methods used to seal and fold the film. There were also challenges stemming from the film’s quality and the printing processes. However, testing and equipment adjustments made it possible to overcome all the obstacles.

Because flexible LDPE packaging is a plastic whose flat shape is similar to paper, facilities have trouble sorting it effectively. And because LDPE is so light, it tends to fly away and get caught in conventional sorting equipment. By working with a company specialized in flexible resin recycling that vertically integrated all of its activities, it was possible to avoid the sorting issues that often arise with flexible plastics. The strategy made it possible to benefit from a good quality recycled material and facilitated its ongoing supply.

Benefits

The ecodesign initiative for the 30-roll toilet paper packaging made it possible to switch from flexible plastic made from 100% virgin materials to plastic made from 100% recycled material. In addition, the packaging’s mass was reduced, resulting in a 3% decrease in the packaging/product ratio. The two improvements led to potential greenhouse gas reductions of 50%.

Optimization actions taken

The seven ecodesign principles detailed above led Metro to ask the right questions and guided its choices towards more environmentally responsible materials.

The transition from virgin materials to the transition from virgin materials to recycled LDPE resin made it possible to offer consumers packaging made from a 100% post-industrial recycled material.

The approach made it possible to reduce the total mass of the packaging by decreasing the weight of five inner sub-grouping films that each contain six rolls. However, because toilet paper bundles are placed directly on pallets and not packed in cardboard boxes, the weight and strength of the outer film had to be increased to ensure adequate protection during shipping. Reducing the total weight of the plastic films by 2.59 g optimized the packaging/product ratio.

  • Appropriate information on the material indicated on the packaging
  • Email
  • Employee meeting
  • In direct consultation with our suppliers
  • By changing suppliers
  • Identification of plastic resin using SPI codes
  • Recycled content indicated on the packaging
  • Environmental certifications and other environmental claims indicated on the packaging
  • Steps to place the packaging in the recycling bin indicated on the packaging
  • Appropriate logos indicated on the packaging
  • End-of-life management options indicated on the packaging

After optimization

50% Reduction in greenhouse gas emissions

100% Increase in recycled content

3% Decrease in the packaging product/mass ratio

3% Decrease in the quantity of material used