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:
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.
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%.