James Colwill

A Holistic Approach to Design Support for Bio-polymer Based Packaging

The growing interest in bio-polymers as a packaging material, particularly from companies looking to reduce their environmental footprint, has resulted in wider adoption. Traditionally the selection and specification of packaging materials was based on aesthetic, technical and financial factors, for which established metrics exist. However with bio-polymers, where the primary rationale for their use is environmental, alternative metrics are required. Furthermore, there is a significant strategic element to the decision process that requires a broader range of horizontal and vertical inputs, both within the business and the wider supply chain. It is therefore essential that a holistic approach is taken to the bio-polymer based packaging design process to ensure that the final packaging meets the original strategic intent and overall requirements of the business. Current eco-packaging design tools are generally limited to professional users, such as designers or packaging engineers, and generally provide tactical rather than strategic support. This disconnect, between the need for inclusivity and greater strategic support in holistic design, and the exclusivity and largely tactical support of current eco-design support tools, indicates a clear need for a new decision support tool for sustainable pack design using bio-polymers. This paper proposes a framework for an eco-design decision support tool for bio-polymer based packaging that has been developed using a predominantly qualitative research approach based on reviews, interviews and industrial packaging design experience and is an extension of previously published work. This research investigates further how existing eco-design methods, such as the ‘Balanced Score Card’, can be applied within the tool and how the shortcomings associated with incorporating social and environmental aspects can be partly resolved, through a simplified set of metrics tailored specifically for bio-polymer packaging decisions. The results of this research is a framework for the development of a three tier eco-design tool for bio-polymer packaging that provides decision support at the three critical stages of the design process: strategic fit, Feasibility assessment and concept/pack development.

A Methodology for Sustainable Management of Food Waste

As much as one-third of the food intentionally grown for human consumption is never consumed and is therefore wasted, with significant environmental, social and economic ramifications. An increasing number of publications in this area currently consider different aspects of this critical issue, and generally focus on proactive approaches to reduce food waste, or reactive solutions for more efficient waste management. In this context, this paper takes a holistic approach with the aim of achieving a better understanding of the different types of food waste, and using this knowledge to support informed decisions for more sustainable management of food waste. With this aim, existing food waste categorizations are reviewed and their usefulness are analysed. A systematic methodology to identify types of food waste through a nine-stage categorization is used in conjunction with a version of the waste hierarchy applied to food products. For each type of food waste characterized, a set of waste management alternatives are suggested in order to minimize environmental impacts and maximize social and economic benefits. This decision-support process is demonstrated for two case studies from the UK food manufacturing sector. As a result, types of food waste which could be managed in a more sustainable manner are identified and recommendations are given. The applicability of the categorisation process for industrial food waste management is discussed.

A framework for material flow assessment in manufacturing systems

Improving material efficiency is widely accepted as one of the key challenges facing manufacturers in the future. Increasing material consumption is having detrimental impacts on the environment as a result of their extraction, processing, and disposal. It is clear that radical improvements in material efficiency are required to avoid further environmental damage and sustain the manufacturing sector. Current resource management approaches are predominantly used to improve material consumption solely in economic terms. Meanwhile, environmental assessment methodologies can determine sources of significant environmental impact related to a product; however, a methodology to effectively assess material efficiency in production systems is currently not available. This paper highlights the benefits of material flow modeling within manufacturing systems to support advances in increased material efficiency, proposing a framework for “material flow assessment in manufacturing” that promotes greater understanding of material flow and flexibility to explore innovative options for improvement.

How to manufacture a sustainable future for 9 billion people in 2050

There is a growing body of evidence which increasingly points to serious and irreversible ecological consequences if current unsustainable manufacturing practices and consumption patterns continue. Recent years have seen a rising awareness leading to the generation of both national and international regulations, resulting in modest improvements in manufacturing practices. These incremental changes however are not making the necessary progress towards eliminating or even reversing the environmental impacts of global industry. Therefore, a fundamental research question is: ’How can we meet the long term demand of our growing global population, and in this context, what are the key challenges for the future of manufacturing industry?’ A common approach adopted in such cases is to utilise foresighting exercises to develop a number of alternative future scenarios to aid with long-term strategic planning. This paper presents the results of one such study to create a set of ’SMART Manufacturing Scenarios’ for 2050.

Bio-plastics in the context of competing demands on agricultural land in 2050

Recent trends in the bio-plastics industry indicate a rapid shift towards the use of bio-derived conventional plastics such as polyethylene (bio-PE). Whereas historically a significant driver for bio-plastics development has been their biodegradability, the adoption of plastics such as bio-PE is driven by the renewability of the raw materials from which they are produced. The production of these renewable resources requires the use of agricultural land, which is limited in its availability. Land is also an essential requirement for food production and is becoming increasingly important for fuel production. The research presented in this paper envisages a situation, in the year 2050, where all plastics and liquid fuels are produced from renewable resources. Through the development of different consumption and productivity scenarios, projected using current and historic data, the feasibility of meeting global demands for food, liquid fuels and plastics is investigated, based on total agricultural land availability. A range of results, comparing low-to-high consumption with low-to-high productivity, are reported. However, it is from the analysis of the mid-point scenario combinations, where consumption and productivity are both moderate, that the most significant conclusions can be drawn. It is clear that while bio-plastics offer attractive opportunities for the use of renewable materials, development activities to 2050 should continue to focus on the search for alternative feed stocks that do not compete with food production, and should prioritise the efficient use of materials through good design and effective end-of-life management.

Eco-Design Tool to support the Use of Renewable Polymers within Packaging Applications

Bioplastics derived from renewable polymers such as sugars, starches and cellulose, have attracted significant interest from companies looking to reduce their environmental footprint. New production capacity and improved materials have resulted in their increasing adoption for mainstream consumer products packaging. However questions remain regarding their overall environmental benefits and how the maximum environmental gain can be achieved. These uncertainties highlight the need for a decision support tool to aid the packaging design process. This paper examines the issues surrounding bio-derived polymer use and discusses the development of an eco-design tool to assist in their rapid and efficient adoption.

Additive manufacturing as a strategic tool for industrial competition

Additive Manufacturing (AM), often misleadingly referred to as 3D Printing (3DP), comprises of a group of technologies whose initial inception occurred over thirty years ago within the product design and development applications for the rapid prototyping of concepts, primarily using polymeric materials. Over the past few years AM development has increased exponentially and 3D Printing has expanded to include new areas of research such as 4D Printing, Nano AM, Contour Crafting and so on. However, a proper understanding of the technologys actual and potential benefits to industrial manufacturing has not been approached by practitioners and researchers in detail and industrial end-users risk missing the opportunity to make competitive choices due to the lack of an impartial and realistic overview. Real and tangible industrial benefits are often misunderstood due to the dissemination of information delivered with a mindset grown on a maker-side market, which misses to scope for AM in industrial applications. The aim of the paper is presenting a detailed overview of AM applications in the industrial world, focusing on the likely impacts on organizations and, moreover, to highlight and discuss the potential employments of the technology within the industrial value chain.

Societal benefit assessment: an integrated tool to support sustainable toy design and manufacture

The final publication is available at IOS Press through http://dx.doi.org/10.3233/978-1-61499-668-2-381

A framework and decision support tool for improving value chain resilience to critical materials in manufacturing

Abstract Certain non-energy materials have been identified as being critical to the manufacturing sector and wider economy due to having a high risk of supply disruption combined with high economic importance. The criticality of specific raw materials is becoming increasingly acute as the escalating use of resources is driven by an increasing global population. Critical materials are vital elements in the value chain yet their supply risk may often be ineffectively addressed by traditional supply chain management strategies. Most research to date has been focused at a national or industrial policy level thus many manufacturers are unaware if their operations are at risk from critical materials at a product level. This paper presents a framework that takes a systematic approach to identifying, assessing and mitigating risk associated with critical materials bilaterally along the value chain to facilitate manufacturers in the identification, assessment and mitigation of critical material supply risk. This paper also describes how the framework can be facilitated for application in industry through preliminary design specifications towards a development of a decision support tool.

An integrated tool to support sustainable toy design and manufacture

Abstract Whilst the importance of considering the positive societal benefits of a product, in addition to other social, economic and environmental factors, has received wider recognition, its definition, concept, and integration into product design are not so well developed and studied. A literature review on sustainable design identified the potential of Social Life-Cycle Assessment as a tool to measure societal benefits of products; however further analysis of sustainable assessment methods highlighted the lack of a coherent definition and method for achieving this. This paper presents a framework for including societal benefits within a product portfolio management process and a prototype tool which aims to support the implementation of the framework within the toy industry, specifically on the societal benefit assessment of the products during the first stage. Finally a simulated case study of three toys is used to exemplify the intended application of this tool and to support the concluding discussions.