Loadshedding

Although Gaborone is only 360km from Johannesburg, loadshedding does not seem to affect life in Botswana the way it does in South Africa. With most of its electricity being produced by coal-fired power stations – and a small percentage sourced from other Southern African countries – Botswana has only experienced one period of occasional blackouts since 2015. However, South Africa, as we know, has a completely different experience.

In fact, since September 2022, every month has been in crisis mode with March 2023 the only sign of improvement. This puts a lot of pressure on businesses, as productivity is interrupted and reduced to certain times of the day. Loadshedding during material extrusion would burst the bubble of film and cause a lot of waste, not to mention the time it takes for the heaters to cool-down and warm-up again once power is restored. Luckily, we are only rarely affected by loadshedding and therefore, production runs smoothly and our deadlines are more consistently met.

Barrier films

Being in the barrier-film industry, ensuring barrier quality and product dependability are two of the most significant factors. The main barriers would be nylon, EVOH, or a combination of the two for more complex barrier-films. To us, the industry standard has always been 8µ (I.e., micron/thickness) nylon in 70µ vacuum bags, which maintains the OTR (oxygen transmission rate) and therefore, the shelf-life of the packaged goods. This is essential as any factors that impact the shelf-life of the product can lead to loss of sales, wasted goods, reputation, and health concerns.

As part of our R&D, we conduct regular laboratory tests of various products in our industry; we need to compare what we know of our potential clients’ needs in comparison to what they are being supplied. The lab tests, on several occasions, have revealed that the packaging in use is different to what has been reported, or less than the industry standard. For example, tests on vacuum bag material have shown a reduction from 8µ to 6µ nylon, which would ultimately impact barrier properties. Although it might be sufficient for certain goods or within some food logistics in the supply chain, it is important to understand what one’s need is compared to what is being received.

Technical expertise

As you will notice on our website, we have stated that we have 40 years of experience in the flexible film industry. In addition, Sun Plastics is the heart of a group of companies that operates in several South African countries, which all contribute towards the various packaging requirements in our region. While our world-class facility hosts a range of modern machinery and BRC processes, the people behind the company are just as important.

That being said, Sun Plastics offers:

• A skilled sales force
• Expert operation managers in print, production, and quality control
• An internationally educated CEO with a dynamic approach to management, production, and business development
• A hands-on approach to new business development and a constant drive to pursue the most innovative product solutions
• A consultant with 40 years’ experience in the packaging industry as well as technical experience in food packaging systems
• A marketing programme dedicated to providing industry knowledge, relevant information on packaging sustainability, and driving the mission of the company

We are committed to delivering exceptional sustainable packaging solutions while upholding the highest standards of product quality. We invite you to explore our diverse range of products and discover how we can revolutionise your experience.

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The International Context

The international trade of plastic products is considerable. According to the United Nations Conference on Trade and Development (4), plastics trade would be the 4th largest exporter in the world if it were its own country.

“It would take 18.4 million trucks, each carrying 20 tons, to deliver the 369 million metric tons of plastics exported in 2021. The queue of trucks would wrap around the globe 13 times” (4).

As shocking as it sounds, this does not only constitute the trade of virgin plastics/finished goods. Due to global inequality, a significant percentage of plastic waste is exported as well. In fact, developed countries are responsible for 80% of the global waste trade, which ends up in developing countries who are unable to manage this waste appropriately (4). However, if each country was responsible for processing their own waste, then there might be a shift towards more efficient production, reduced consumption, as well as improved waste management.

The Local Context

In South Africa, the plastics’ industry is predominantly focussed on the packaging sector. According to the Department of Trade, Industry and Competition (2), plastic packaging accounts for 52% of the local market, but there is still a short supply of polyethylene blends such as PE-LD, PE-LLD and PE-HD. The DTIC also reports a trade deficit, which includes low value plastic imports as well as the importation of finished goods that have the same construction as goods that are exported. While we rely heavily on cheap imports, we stifle the opportunity for domestic growth of the plastics manufacturing sector.

Two of the five key areas for growth (2) can be addressed by Sun Plastics: food packaging and medical products. With capabilities for both mono-layer and coextruded barrier films, Sun Plastics has the expertise and technology to target these areas effectively. In addition, we are a level 2 contributor to B- BBEE and hold an ‘A-rating’ for BRC accreditation. Therefore, our areas of expertise can help develop 2 areas of growth in the packaging sector, our business activities and management structure have a positive effect on socio-economic indicators, and we have yearly audits to ensure our production methods meet international standards.

Certification is based on the following:

Manufacturing of flexible laminates using PE, PA, APPEEL, BOPP (transparent, metallized, pearlized), PET (transparent, metallized), CPP, aluminium foil by blown film extrusion (7 layer), Printing (CI Flexography), Solvent Less Lamination, Slitting in rolls, bags and pouch and shrink films using PE by blown film extrusion (7 layer) for use in food and non-food applications.

When we say ‘local’, we mean local to the region as sourcing material from Botswana is very different to imports from overseas. Our market research shows that the main overseas sources are Israel, Turkey, China, and Russia; the minimum distance would be at least 10 000km. However, Gaborone’s link to several major cities in Southern Africa is a lot shorter:

• Johannesburg, South Africa – 370km
• Windhoek, Namibia – 1100km
• Harare, Zimbabwe – 1070km
• Maputo, Mozambique – 890km

The benefits are not based on distance and carbon footprint alone. Being members of the Southern African Development Community (3) and the African Continental Free Trade Area (1) means that there are more incentives for localised trade, such as reduced trade barriers, regional integration, and sustainable development.

For all your biodegradable plastic packaging solutions for your business or personal use, get in touch with Sun Plastics. We have a wide range of sustainable packaging solutions to suit your needs. Contact us today.

References

1. Africa Business. (2017). What you need to know about the African Continental Free Trade Area. https://african.business/2022/02/trade-investment/what-you-need-to-know-about-the-african-continental-free-trade-area

2. Department: Trade, Industry and Competition Republic of South Africa. (n.d.). Plastics. http://www.thedtic.gov.za/sectors-and-services-2/industrial-development/plastics/

3. Southern African Development Community. (n.d.). The main aim is to achieve development, peace and security, and economic growth, to alleviate poverty, enhance the standard and quality of life of the people of South Africa. https://www.sadc.int/

4. United Nations Conference on Trade and Development. (2022). Global plastics trade hits record $1.2 trillion. https://unctad.org/data-visualization/global-plastics-trade-reached-nearly-1.2-trillion-2021

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In a paper titled Planetary Boundaries: Exploring the Safe Operating Space for Humanity Rockström et al., (2009) identified 9 planetary boundaries that are interconnected and therefore, under threat from the destabilising effects of human behaviour. With that being said, a holistic approach is necessary to understand how our impact ripples across the natural systems of our planet.

For a better understanding, the planetary boundaries (Rockström et al., 2009) are listed as follows:

• Climate Change – loss of polar ice sheets and increase of atmospheric CO2 levels
• Ocean Acidification – decimation of coral reefs and reduction of ocean pH
• Stratospheric Ozone – UV radiation
• Global Phosphorus and Nitrogen Cycles – fertiliser production and crop cultivation
• Atmospheric Aerosol Loading – impacting atmospheric circulation (e.g. monsoon systems)
• Freshwater Use – surface and groundwater
• Land Use Change – conversion of land to cropland
• Biodiversity Loss – including damage to ecosystems
• Chemical Pollution – emissions and pollutants

The point is not to describe our impending doom in detail, but rather to illustrate the various natural systems that have been highlighted in sustainability research in order to raise awareness. Therefore, when one hears about ‘corporate sustainability’ and ‘environmental degradation’, there is more understanding and context of the sustainability narrative.

Corporate Sustainability

Business and economic activities are factors that can play a big part in sustainable development. With the current global economy being built on a foundation of globalisation and consumption, reinventing the norms of production and trade can create a more stable foundation on which to grow.

It is now commonly understood that fuelling the aspirations of a growing global population – the provision of housing, mobility and food, electricity and water and modern consumer goods – will not be possible without very large improvements in the material and energy efficiency of the global economy. (Schandl et al., 2016:11)

However, with the international arena being a complex web of trade and economic transactions, this is no easy task. Therefore, one should strive to learn about their position in the Anthropocene (era of humanity’s impact on the earth), how our actions and interactions shape the environment, and then confidently support ways in which to improve our behaviour and attitudes. Regardless of who your supplier is, it is important to understand the hidden costs behind the choices we make. This means where we source our materials from, how they are produced, the logistics involved, the working environment and corporate culture, the impact of B2B relationships, as well as the impact on the natural environment.

From our perspective at Sun Plastics (i.e., business, manufacturer, and employer) we actively promote sustainable development in several ways:

Economic

Focusing on the development of the plastic packaging industry in Southern Africa: increasing the market share of locally produced plastic packaging by isolating key areas for product development. Additionally, we procure from local raw material and polymer suppliers, while offering competitive pricing and shorter lead times – in comparison to imports – to our customers. As the company grows, so too shall the capacity for product potential and conversion capabilities to sustainable packaging solutions. That being said, investment in Sun Plastics equals investment in local manufacturing.

Social

Our factory has employed over 140 people from the local community in Gaborone. With upskilling and training opportunities, we are contributing towards a competent labour force and increasing the living standards of our employees and their families.

Environmental

Although we produce traditional plastic packaging, our focus is to reduce impact by localising production and supply, while investing in the latest technologies and machinery to innovate the potential for value added to the industry. For example, we recycle in-house waste, offer recyclable and biodegradable materials, and contribute towards the government’s EPR scheme. 

If you are looking to convert to biodegradable plastic packaging solutions for your business or personal use, Sun Plastics has a wide range of sustainable packaging solutions to suit your needs. Contact us at Sun Plastics today. 

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Getting our materials tested

We are currently in the process of having our biodegradable materials tested; a local and comprehensive analysis of the performance of our packaging. Although the additive has been tested previously, our discussion with the CSIR has prompted us to pursue independent laboratory testing of our own manufactured material. This means that we will provide several samples to be tested under various types of environmental conditions, to verify our claims within the market. This would take place under accelerated landfill conditions, a marine environment, as well as soil.

The tests are also divided into three stages: fragmentation, biodegradation, and toxicity. This process will confirm if the material breaks down in a certain timeframe, completely degrades, and that the end result is not harmful to the environment. It is paramount that the materials meet international standards and complies with market regulations.

Biodegradable regulations in South Africa

It seems that there aren’t any formal laws (i.e., hard laws) regarding biodegradable and compostable materials in South Africa. This conclusion is based on information received from local government and interest groups, as well as research papers. Most notably the 2020 position paper titled Biodegradable and Compostable Packaging: a review of the South African landscape, raises key points in terms of biodegradable and compostable packaging (The Moss Group, 2020, p. 3-4).

• Currently the restriction of separation, collection and processing infrastructures do not help direct post-consumer management of plastic packaging solutions (para. 4).
• Presently, there is a shortfall for legislation concerning particularly to biodegradable and compostable materials in South Africa, with SANS 1728:2019 identification requirement of degradable plastic marking as the exclusion (para. 5).
• The South African public do not have proper knowledge and understanding of what biodegradability and compostability means (para. 6).
• The majority of the raw materials i.e., resins, and some finished products are imported, whereby the South African Economy is being restricted (para. 7).

Phasing out unnecessary products

Since the above paper was released, there have been two significant developments that have attempted to curb plastic waste in South Africa: SA Plastics Pact and the EPR Levy. Although we have mentioned these both before, it is worth noting that the Plastics Pact is in the process of phasing out 12 products that are regarded as problematic and unnecessary. The collaboration between the plastic industry, business, and government has identified products such as single-use cutlery, thin-barrier fruit bags, as well as products manufactured with oxo-degradable additives.

Although our additive is a much newer and improved technology – and is currently an accepted biodegradable material – we continue to review the potential impact and relevance of our biodegradable material in the market. By undergoing testing that complies with the American Society for Testing and Materials (ASTM) and the International Organization for Standardization (ISO), we ensure that our claims are backed by rigid scientific processes. Additionally, this experience will allow us to continue learning and to be responsible custodians of the biodegradable materials industry.

Switching to biodegradable packaging solutions allows you to play your part in helping the environment. If you think there is potential for converting your packaging requirements to a biodegradable option, then get in touch with us to explore the solutions together.  

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We are happy to announce the launch of our first retail product: biodegradable refuse bags.

After years of R&D in this market segment, we have created a product that has innovated the way we deal with waste – literally. By taking an ordinary household product, we have transformed it into something with added properties and value. This is the first step in our sustainable transition towards flexible packaging.

What is a biodegradable refuse bag?

While our refuse bags are very similar to others on the market: recycled polyethylene that is extruded to a thickness of either 18 or 20 microns. What makes our material special is the additive that is used during the manufacturing process. This additive allows the material to break down when discarded in a landfill or the natural environment. When activated, it begins to soften the polymer chains (i.e., the structure of the plastic), which makes it available for natural microorganisms to eat. According to the scientific data, the biodegradation rate should enable the complete breakdown of the material after 5 years. This is a game-changer, as our waste removal practices will remain unchanged, but our waste management is improved.

State of South African Landfill’s

Leon Grobbelaar, from the Institute of Waste Management of Southern Africa (IWMSA), has said that landfills in South Africa are close to reaching capacity. This is made worse by the lack of municipal expertise and inefficient on-site management. According to him, “Johannesburg has a maximum of three years left until its landfills reach capacity”. With an increasing population and demand for packaged goods, innovation needs to occur at every level of the value chain. This includes manufacturing, consumption, and waste management. Plastic is a valuable resource – and with it being so embedded in modern society – the opportunity to reduce waste through effective end-of-life strategies (biodegradability and recycling) is a significant step in the right direction.

Where to find our refuse bags?

The biodegradable refuse bags are specially manufactured for Pira Retail, our partners and the distributors of these products. If you are interested in adding these bags to your product list, get in touch with us through our website or via email.

We would be more than happy to answer any questions or queries you may have. There is also a QR code on the artwork which, once scanned, will lead you directly to the biodegradable page on our website for additional information.

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Lamination & Print

Colour plays a significant role in the perception of your product or designs. Based on colour psychology, each colour can trigger different emotions and prompt different actions. Therefore, the design and quality of the print are essential. It needs to be both visually striking and appealing to the eye. This is to ensure that a product can compete with its competitors. With the help of the biggest packaging designers on the continent as well as a 10-colour Uteco printing machine, Sun Plastics can do your product the justice it deserves.

Additionally, we produce laminates for added barrier properties and product quality, and to prevent ink migration into the packed goods. So, whether you require mono-layer print or multi-layer laminates, Sun Plastics can offer the best options for your product applications.

Biodegradable or Recyclable

There are various ways in which sustainability can be analysed that can be extremely complex. For example, one may source a product that is cost-effective but is imported from China, or a product that is marketed as a green alternative but requires specific waste management processes. In this case, we find that unpacking this complexity while producing high-quality products creates great value for our customers.

The goal is to meet our customers’ requirements within an industry that seeks to move towards a greener economy. Which is where we are starting to see growth. The biodegradable additive that we use would not activate within the recycling stream, therefore, Sun Plastics can offer both biodegradable and recyclable mono-layer variants. These can be plain or printed and support the recyclability of plastic while also addressing waste management issues when the materials find their way into the natural environment.

Hidden Costs

From experience, we have found that the cost of packaging is an important factor – if not the most important – when choosing between potential suppliers. In most scenarios, imports are very competitive but should only be viewed by this characteristic. The reason is that one cannot claim to address environmental concerns when imports are favoured over the same materials being produced closer to home.

The same logic would also mean that quality/application cannot be claimed as the top priority. Especially if generic packaging is favoured over innovation (i.e., biodegradable). Even if there is a slight increase in material cost, addressing the hidden costs of environmental degradation makes biodegradable or recyclable products a lot more valuable.

To illustrate this effectively, one would only have to look at the rate of biodegradability in comparison to generic packaging. If one had to use the same volume of both variants for 5 years (e.g., 100MT per year), the waste of generic packaging would equate to 500MT or 100%, while the biodegradable material would be around 100MT or 20% after 5 years.

Understanding the industry and knowing exactly what you’re getting is important. With over 40 years of experience in the manufacturing of flexible packaging in Southern Africa, Sun Plastics is the company to keep you informed. Get in touch with them for high-quality packaging solutions.

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According to National Geographic about 80% of that pollution and trash originates from land sources – “littering, storm winds, and poor waste management”. This illustrates that our biggest problem is not necessarily the existence of plastic but rather how to manage it responsibly after we have disposed of it. What makes this even more complicated is how easy plastic is to produce, as well as its durability and barrier properties. A product that has become such an integral part of our ecosystem but can have such a detrimental impact if not managed effectively. It is a tragic issue to face as humanity attempts to balance the demands of a growing population with sufficient waste management infrastructure and services. For lack of a better word, it’s unsustainable.

Possible solutions

However, it is not all doom and gloom. In our previous theme on the EPR levy, we noted a great push for investment in the recycling industry that would help address these issues. By increasing the flow of recyclable products into the recycling stream, we can keep the value of these materials in circulation and reduce unnecessary landfill dumping. Other products, such as refuse bags, could be redesigned as they are certainly destined for landfill and no innovative end-of-life management exist. There is a case to argue that they should be converted to biodegradable variants – certified according to international standards. Therefore, our waste management becomes dynamic: diverting as much as possible from landfills but also creating ways in which to reduce landfill mass.

That simple right? Not just yet

One should also consider the complex constructions; the multi-layer plastics that aren’t currently or readily recyclable (e.g., resin code #7). These could be co-extruded materials like vacuum bags or thermoforming film, that are based on a polyethylene (PE) and nylon (PA) blend. While it has been long understood that these materials are not recyclable, new evidence has come to light that suggests the contrary. BASF, a multinational chemical manufacturer, conducted a study earlier this year where they attempted to investigate the potential to recycle a PE/PA mixture. The paper titled ‘Coextruded PE/PA multilayer films are recyclable!’ revealed that certain requirements would need to be met (e.g., the ratio of the blend as well as additives) but that this combination is ultimately recyclable.

However, in saying that, both the technology and infrastructure need to be available to process the material effectively. This isn’t possible within South Africa according to several sources. The same could be said for bioplastics, both biodegradable and non-biodegradable. Both of which require specific end-of-life conditions for effective waste management. Also, “despite numerous academic research efforts to promote the application of biodegradable polymers in packaging, there are few bio-based/biodegradable polymers in the market that can meet the high demand for food packaging within modern society”. (Wu, Misra, and Mohanty, 2: 2021).

Taking the above into consideration, Sun Plastics is continuously looking at ways in which we can add value. Whether this is providing high-quality barrier film and biodegradable variants according to the most effective market segments, or through the research and information supplied through our marketing programme. We want to be up to date with what’s happening in the market, and we want our customers to be well-informed.

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Although Sun Plastics has the capabilities to produce a range of flexible plastic products, we focus on manufacturing high-quality barrier films for several applications such as food and medical products. Therefore, to help one navigate EPR, Sun Plastics have noted a few points that we hope will assist both the consumer as well as the product manufacturer. Having a better grasp of the packaging in use can have a positive influence on economic, social, and environmental sustainability.

Here are 3 points to consider:

• 1. Know your material
  

  Plastic packaging comes in various shapes, forms, and sizes; some are easily recyclable while others are not. The number on the packing (1-7) is the resin code, which helps consumers assess the construction and how the waste is to be disposed of (i.e., either in your recycling bag or in your refuse bag destined for landfill). Plastics SA reports that numbers 1-6 are currently recycled in South Africa, but most recycling centres are only equipped to process #1, #2, #4, #5, #6 according to the South African Plastics Recycling Organisation (SAPRO). Luckily, food manufacturers/retail brands such as Woolworths are making it easier for their customers, by correctly labelling the various components of their packaging with “widely recycled in SA” or “not currently recycled”. While that is helpful in terms of waste management, it is up to us as packaging manufacturers to constantly explore how we can lead the market in product innovation and sustainable development.

• 2. Know your application
  

  Due to our production of specialized barrier films, Sun Plastics currently focuses on coextruded and laminated materials – resin code #7. These products are necessary as they are puncture-resistant, have increased barrier properties against moisture and air, and are also converted into various ways for our customers’ application requirements. This could be rolls for FFS (form, fill, and seal) and thermoforming (I.e., meat and cheese) systems, or even in various sized pouches/bags. All these constructions can be tweaked and printed to specific requirements however, it is important to know what these requirements are. For example, our R&D has shown us that there are industries that may rely heavily on EVOH – which is a high barrier resin – even though they only require a much shorter shelf-life. The consequence of this could be an increased cost, the reliance on a rare material, or even the increase of product weight due to the construction. One should take all of these things into consideration as an increase in weight would mean more plastic in use and a higher levy.

• 3. Know your thickness requirements

  Although quite similar to the previous point, it would also be important to ensure that you are using the right micron/thickness material. By “right” we mean using a material that offers all the barrier properties and durability that you require, but that has the right thickness to achieve this. Sun Plastics can assist; taking your current spec and application, we can conduct the relevant trials to ensure that your product is suitably packaged and that you aren’t paying more than you should. For example, a medium sized company using an additional 20 micron in one variant could see an additional cost of R60 000 per year.

Having a better grasp of the packaging in use can have a positive influence on economic, social, and environmental sustainability. Get in touch with Sun Plastics for innovative, and advanced barrier flexible packaging.

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Whether you have heard it at a local market while buying gourmet foods or seen it on some packaging at the supermarket, this is a phrase that we are all familiar with. It is an ideology that most people seem to share and try to uphold, which allows entrepreneurship and economic growth to prosper in Southern Africa.

However, to what extent do these values really hold true?

It should, and here’s why:

1. Our material is high-quality

2. Our value chain is localised

3. Our footprint is significantly lower

The post The importance of local production  appeared first on Sun Plastics.

Educate your customers

Start off by first educating your customers on how alternative biodegradable packaging will help amplify sustainability efforts. Inform them of the harms of conventional plastic packaging and the benefits of switching to sustainable packaging. You could use social media platforms or email newsletters to raise awareness to your customers. By providing your customers with clear information, you can prevent any confusion or concerns. A good option, to relay this information, is to enclose an insert with information on sustainable packaging inside current packages. This will help keep your customers well-informed on your journey towards using sustainable packaging.

Find a reliable supplier

After you have made your customers aware of your new venture, do your research. Packaging alternatives that facilitate composting and biodegradable processes will increase sustainability efforts in your business. When you produce biodegradable materials, an additive is mixed in with other raw materials. That is then extruded into material and converted into your desired product (e.g., bags, rolls). When you dispose of it in a natural environment (water / soil), the polymer chains are broken down through water or air. This process softens the strength and barrier of the plastic, which then becomes a food source for the microorganisms and nature eats the plastic. It is then converted to natural elements: carbon dioxide, methane gas, and water. Always make sure to ask your supplier and manufacturer details about their processes used.

Introduce your new biodegradable packaging

After you have found a reliable supplier who has given you sufficient information on how biodegradable packaging is produced, it is time to make the switch to biodegradable packaging for your business. Start by slowly phasing out your old and unsustainable packaging materials. This will take some time, so you need to be patient. Inform your customers of the changes to biodegradable packaging and your goals to reach a sustainable eco-friendly business. Encourage your customers to share your products online to raise awareness. Remember going green is good for your business and the environment.

Converting to biodegradable packaging is an alternative to the current plastic production trajectory. It will also help your business expand its brand to new markets and may even increase your sales. If you think there is potential for converting your packaging requirements to a biodegradable option, then please contact us to explore the potential solutions together.

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