Vox pop: Have we reached our lightweighting limit?

Yes: It is great to have achieved this lightweighting milestone while still delivering product performance. However, we are probably close to the limit. Prior to this, cans were already the lightest pack choice for carbonated beverages, making them a sustainable package with huge environmental benefits.

The recycled content of the can is already higher than any other beverage pack and continues to increase, bringing additional environmental benefits. For example, it takes 95% less energy to make a can from recycled aluminium. So, although we may be close to the limit for light-weighting, the can’s strong environmental story continues.

Doug Johnson, managing director, Packology

No: Absolutely not. I do think that some of the big players like Coca-Cola have probably got as far as they can get in their own processes. But there are hundreds of medium-sized businesses and tens of thousands of smaller users of packaging who could do much more, and that covers any material, be it corrugated, cartonboard, glass or whatever.

There is a focus on unit price rather than full life-cycle cost and companies don’t necessarily understand that lightweighting could save them money, too. Also, my experience is that specifiers in the Far East and the US are not doing as much to lightweight as they could. But the onus should be on suppliers. There are lots who are happy to take the order but won’t challenge specifications that could be five or 10 years out of date.

Nicola Bennett, sustainability projects manager, Corus Steel Packaging Recycling

Yes: Lightweighting is one way to reduce the environmental impact of packaging, but its benefits are limited. Take it too far and we could risk rendering packaging unfit for protecting products and aiding distribution. That is not to say we can’t improve green performance, but additional factors, such as the lifecycle of the material itself, must also be considered.

Steel food cans are now 24% lighter than they were 30 years ago and drinks cans are 31% lighter but, more importantly, they are made from a sustainable, renewable material. All steel packaging is 100% recyclable and can be infinitely recycled. It is also made from some of the most abundant materials on earth: iron ore, coal and limestone. Furthermore, 95% of local authorities collect steel packaging at kerbside resulting in an impressive recycling rate of approximately 69%.

Nick Kirk, research manager, British Glass

No: In the glass sector, the Wrap-funded GlassRite projects have achieved a glass weight reduction of more than 60,000 tonnes per annum over an 18-month period, with many brands achieving more than 20% weight reduction. These initiatives have shown that there is definitely further potential to lightweight using existing glass manufacturing techniques.

The technology that has yielded the largest glass weight saving has been the use of narrow neck press and blow (NNPB) for the production of beer, spirit and wine bottles. In addition advances in mould and plunger materials, along with better process monitoring and controls have all contributed to recent successes.

By adopting the latest forming kit, the industry will be able to develop tech-nologies such as single-stage forming and coatings to increase strength.

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