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CLOSING THE LOOP: From Waste To Product. Anthony J. Gallo , CCP – Senior Director of Sustainability & Applications Development. Agenda. Associated Packaging Overview Manufacturing Products Customers Sustainable Leadership – RePET Background Supplier selection Manufacturing challenges
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CLOSING THE LOOP: From Waste To Product Anthony J. Gallo, CCP – Senior Director of Sustainability & Applications Development
Agenda • Associated Packaging Overview • Manufacturing • Products • Customers • Sustainable Leadership – RePET • Background • Supplier selection • Manufacturing challenges • APT’s Sustainable outlook • Conclusions
PLASTICS, BENJAMIN - Mr. McGuire, The Graduate -1967
APT Overview • The world leader in dual-ovenable, CPET containers, providing over 2 billion trays per year to the food processor and food service industries. • Wide array of stock tray options and complete customization capabilities, with industry leading speed-to-market • APT ranked top 10 Thermoformers in North America by plastic News • Founded in 2003 in Kitchener, Ontario • www.APTechnologies.com
Cambridge, Ontario Cambridge, Ontario Marshall, MO Chillicothe, MO Chillicothe, MO Waynesville, NC Waynesville, NC Fayetteville, AR Batesville, AR Russellville, AR APT Locations • Headquartered in Chadds Ford, PA • Four plants; three in North America and one in Carrickmacross, Ireland serving Euro market • Engineering in NC • Rapid prototyping capability in Cambridge, Ontario Carrickmacross, IRE
APT Overview • 2009 turnover of $160M • Waynesville, NC plant $53M • 500 employees worldwide • 80 employees in Waynesville, NC
Sustainable Leadership - RePET • APT recognized the industry’s need for a sustainable packaging solution and began development of RePET for dual-ovenable tray use in 2006 • Evaluated over 30 different RePET suppliers in Europe and North America • APT selected NURRC and their Ultra-Clean technology on both continents. Worked jointly to qualify for a letter of non-objection for up to 100% RePET in our trays • Commercial at 40% RePET, 100% RePET proven
Sustainability Leadership- RePET • Significant capital investments were made in equipment to improve processability and efficiency in RePET • Optimized tray design as required to facilitate use of RePET • RePET was first introduced commercially in the UK market in 2007 • With product performance and quality paramount, APT was able to deliver up to 40% PCR at the same price
Sustainable Leadership Cont… • This has resulted in over 12MM pounds of RePET in 2009 with a growing number of customers in North America and Europe • Equivalent to removing 5,404 cars from the road for 1 year • Corresponds to over 428MM single-serve water bottles* • Industry Recognition • The 2008 Ameristar Award • 21st DuPont Award for Packaging Innovation • 2009 SPE Environment Stewardship Award *based on average bottle weight of 12.7g in 2008 Beverage Marketing Corporation study for IWBA. Published in FoodBev.com
2008 US PET Bottle Recycling Rate Source: NAPCOR
RPET Usage Product Categories Source: 2008 NAPCOR Report on PCR activity
Market Data *Source: NAPCOR Thermoformers council industry audit 1.4 billion lbs* of packaging produced in 2008. Does not include imports. 153 MMlbs post consumer bottle RPET. Market growing rapidly due to naturalgrowth and conversions from PS and PVC. BY 2011, could be half the size of PET bottle market.
Opportunity to Increased Volume Usage • Limited to bottle copolymer • Increased local demand • Increased offshore demand • Retail awareness • Consumer awareness
Proven Case Study Collected 20k lbs of used CPET food trays Cleaned via NURRC process Successfully reprocessed black CPET RePET @ 100% Extraction approved for direct food contact
Conclusions Demand is out pacing supply Feed stock currently limited to PET bottles Growing source of PET feedstock in rigid thermoforms Opportunity to capitalize on valuable resource while reducing waste to landfill
THANK YOU Questions