Usability Works Project A feasibility study of reusable transport and storage systems for large kitchen appliances WRAP commissioned a feasibility study to examine the possibility of replacing the current disposable packaging used for large kitchen appliances with an alternative reusable transportation and storage system.
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Usability Works Project
A feasibility study of reusable transport and storage systems for large kitchen appliancesWRAP commissioned a feasibility study to examine the possibility of replacing the current disposable packaging used for large kitchen appliances with an alternative reusable transportation and storage system.
WRAP works in partnership to encourage and enable businesses and consumers to be more efficient in their use of materials and recycle more things more often. This helps to minimise landfill, reduce carbon emissions and improve our environment.
Contents
1 Introduction 5
2 The Current System 6
3 The Reusable Transportation and 8 Storage System (RTSS)
4 Route forward 16
5 Conclusions 18
6 Bibliography 20
Appendix A 21 Desk research
Appendix B 24 Average weight of primary packaging (large kitchen appliances)
Appendix C 25 Stakeholders and users
Appendix D 27 Cost models for RTS box manufacture
Appendix E 29 Materials research
Appendix F 34 Project risk assessment
Appendix G 37 Sales of large kitchen appliances
Appendix H 38 Reduction in packaging costs
While steps have been taken to ensure its accuracy, WRAP cannot accept responsibility or be held liable to any person for any loss or damage arising out of or in connection with this information being accurate, incomplete of misleading. For more detail, please refer to our Terms & Conditions on our website – www.wrap.org.uk
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Executive summary
WRAP commissioned a feasibility study to examine the possibility of replacing the current disposable packaging
used for large kitchen appliances with an alternative reusable transportation and storage system (RTSS) which
could also provide a means of transporting ‘returns’ and used appliances. The study involved John Lewis as the
retail partner and Electrolux as the manufacturing partner. Involving a manufacturer made it possible to establish
how far back in the supply chain the RTSS could be implemented.
The aim is to effectively design out the use of disposable packaging for large home delivery items, thereby
delivering a significant reduction in household waste. The project seeks to establish packaging principles and
solutions that could subsequently be applied across all large kitchen appliances and white goods, all large home
delivery items, and the broader range of home delivered items.
The study consisted of desk research, in-depth interviews and site visits. Cost modelling was based on three
possible types of design for the prototype (solid box format, flexible/fabric with sold parts, fully flexible/fabric).
The main findings of the study are as follows:
The challenges to be faced in introducing a reusable packaging system for large kitchen appliances could be
overcome. With appropriate preparation and a staged approach (prototyping, trialling and full-scale
production) that involved all stakeholders, such a system stands a good chance of success and is a viable
proposition.
A reusable transportation and storage (RTS) box would offer more protection than current disposable
packaging. This would reduce the risk of damage to the appliance during its transportation and/or during
delivery to the customer, thus reducing the high cost to both manufacturer and retailer of 'loss and returns'.
If widely adopted for large kitchen appliances, packaging waste in the UK could fall by around 39,250
tonnes/year. Other environmental benefits would include reduced use of materials and energy in
manufacturing packaging, less wastage resulting from appliances damaged in-transit and less waste going to
landfill.
One of the keys to success will be the development of a RTS box that is acceptable to all users. An
incremental approach based on consultation, monitoring and assessment at each stage would encourage buy-
in from users and help overcome resistance to change. It would allow designs to be adjusted and adapted
according to user needs, circumstances and project findings.
Another key to success will be a logistics system that ensures the reusable packaging is available in the right
quantities at the right place at the right time. It will be essential to consider the views of all those likely to
come into contact with the packaging and the logistical systems needed to manufacture, sell and deliver the
appliances.
The next stage is a trial of a prototype. Containing the trial within the UK would remove the issue of
backhauling to locations in Europe and facilitate close communication between the retailer, manufacturer and
third-party logistics companies.
Establishing the principle of the RTSS through a successful UK-based trial would provide evidence to broaden
its scope to other product lines and internationally.
Other environmentally appropriate materials under development include:
Starch-based packaging. The starch is derived from renewable plant sources and manufacture of the foam
does not involve the use of ozone-depleting chemicals (the foam is produced by introducing steam into starch
extract). The material is completely biodegradable and, after use, can be mixed with compost, cardboard and
paper waste streams if desired.
Polylactic acid (PLA). This has been developed by a number of companies and is being produced
commercially in the USA by Cargill; Cargill's material is branded as NatureWorks PLA (see
www.natureworksllc.com). This material has been used for applications as diverse as bottles and textiles. Its
property profile is similar to that of PET. The material is from renewable resources and is biodegradable.
Textile-based materials. For the soft-fill wrap-around packaging option, a range of textile based materials
is available including:
hemp;
jute;
Kevlar®;
polyester geotextile;
polyester fleece;
polypropylene geotextile;
straw geotextile; and
textile architecture.
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Table E1. Properties of main materials used in packaging
Type General Characteristics Availability Cost Application advantages Application disadvantages
Plastics/polymers
HDPE Polyolefin plastic
widely used in
injection and blow
moulding. Typical
products
manufactured from
HDPE include
plastic milk bottles,
bottle caps, plastic
crates, plastic
drums and pallets.
Very durable material
widely used because of
its strength, availability
and good thermal
forming properties.
Not fundamentally
affected by its
environment.
Wide temperature
durability.
One of the two most
widely available
plastics.
Can be purchased
from a wide range of
global resin suppliers.
Also available as a
recyclate; this source
of the material is
used for the
production of such
items as plastic
pallets.
Like all plastics, its
price is linked
closely to the price
of oil and therefore
suffers a degree of
instability.
Application is a suitable use
for recyclate.
Offers strength, durability
and the rigidity required for
the structural elements of a
pack.
Wide use for other forms of
returnable packaging
(pallets, bottle crates, etc.)
makes it an ideal candidate
for the concept.
Damaged components can
be recycled.
As the plastic requires
thermal forming (i.e. injection
moulding), the start-up cost
will be high due to the need
to invest in moulds. This will
potentially be in the range of
£80,000 to £150,000, and
thus will need high volumes
to justify the investment.
LDPE Polyolefin plastic
widely used in blow
moulding and film
extrusion. Typical
products
manufactured from
LDPE include shrink
and stretch film,
bubble wrap and
plastic bottles.
Very durable and flexible
material widely used
because of its strength,
tear resistance,
availability, good thermal
forming characteristics
and moisture barrier
properties.
Not fundamentally
affected by its
environment.
Wide temperature
durability.
Does not have the rigidity
of HDPE and is therefore
not widely injection
moulded.
Widely available.
Can be purchased
from a wide range of
global resin suppliers.
Also available as a
recyclate; source of
the material is used
for applications such
as black refuse sacks.
Like all plastics, its
price is linked
closely to the price
of oil and therefore
suffers a degree of
instability.
Application is a suitable use
for recyclate.
Offers tear resistance and
moisture barrier, but not
the rigidity required for the
structural elements of a
pack. But could find
application in as a
protective component
(possibly in bubble wrap
form).
Easily recycled.
The material does not offer
significant structural strength
and therefore would need to
be used with other
materials/components.
PP Polyolefin plastic
widely used in
injection moulding,
Very durable and flexible
material widely used
because of its strength,
Most widely available
resin.
Can be purchased
Like all plastics, its
price is linked
closely to the price
Offers similar advantages to
HDPE.
Can also be foamed to give
Although all its properties are
similar to HDPE, the low
temperature brittleness can
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Type General Characteristics Availability Cost Application advantages Application disadvantages
blow moulding and
film extrusion.
Typical products
manufactured from
PP include film,
bottle and caps,
plastic food
containers such as
yoghurt pots and
margarine
containers, bottle
crates and other
returnable plastic
containers.
availability, good thermal
forming characteristics
and moisture barrier
properties.
Not fundamentally
affected by its
environment, but its
unmodified form becomes
very brittle at low
temperatures ( 0°C).
Has the rigidity of HDPE
and is therefore widely
used in injection
moulding.
from a range of
global resin suppliers.
Also available as a
recyclate.
of oil. It is widely
traded and
consequently the
price suffers a
degree of
instability.
a robust protective
component.
Would be particularly useful
in applications where there
is a formed hinge (PP is
very resistant to repeated
bending).
Can be easily recycled at
the end of its useful life.
Can be converted to a
structural foam, which
might offer good protective
qualities to the returnable
pack.
Strapping would be another
application for this material.
cause problems. It is
therefore not widely used if
temperatures are likely to fall
to around freezing point.
PET Known as PET
when used for
plastic bottle
manufacture and
polyester when
used as a film or in
textiles. Widely
used for soft drinks
bottles, ready meal
trays, in textiles
and carpet
manufacture.
Very wide application in
both the packaging and
textile industries.
An extremely strong
plastic with good clarity
and barrier properties.
Easily recycled and there
are established markets
for it as a recyclate such
as filling for jackets,
sleeping bags, soft
furnishings and carpet
manufacture.
This plastic is only
likely to be used in
this project as
recyclate. Recyclate is
generally restricted
only by supply.
Cost of recyclate
tends to follow the
cost of the virgin
resin at around
60% of the price of
virgin material.
Application is a suitable use
for recyclate.
When in the form of fibres
has strength and maintains
its 'volume', i.e. it is not
prone to collapse and thus
could be valuable as a
padding material in a
protective component.
PET foam is also being
developed and this may
also bring some structural
strength.
PET pallets are available.
Because of its strength,
also used for strapping.
It is a relatively expensive
material with a lot of
competing markets. It is not
therefore a material that is
used widely for injection
moulded components where
an alternative such as HDPE
may be more realistic.
Timber (including plywood and MDF)
Timber Widely used
packaging material
on both its natural
Used for its strength,
rigidity and ease of
conversion.
Renewable resource,
widely available in
natural and
Cost is not normally
a concern in its
use.
Low capital cost to
manufacture a suitable
timber-based returnable
There are international
restrictions on wood
packaging material (WPM).*
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Type General Characteristics Availability Cost Application advantages Application disadvantages
form and processed
forms such as
plywood.
Commonest
material in tertiary
packaging, being
the most cost-
effective material
for pallets and box
pallets.
Very cost-effective in
broad areas of packaging
such as export, defence
and machinery packing.
Some of its
disadvantages limit its
use in some areas of
packaging.
processed forms.
Timber packs
designed for closed-
loop returnable
systems are well-
established and often
designed for the
particular product.
pack.
Life of the pack likely to be
less than a plastic
equivalent but more than a
corrugated board pack.
Repair may be an option.
Can be a health and safety
hazard.
Not as tolerant of its
environment as plastic,
although considerably better
than corrugated board.
Metal (galvanised steel and aluminium)
Metal Suitable materials
for returnable
packaging systems
where their
strength, rigidity
and ease of
forming are
advantageous. The
choice between
aluminium and
galvanised steel
often balances cost
against weight (Al
is significantly
lighter but more
expensive).
Provides the ability to
fabricate a rigid
framework for a large
returnable pack.
Extremely long life if
treated well.
Can often be repaired to
extend useful life.
Traded
internationally.
Both Al steel are
economically
recyclable, enabling
any metal-based pack
to be both
manufactured from
recycled material and
ultimately recycled.
Costs fluctuate.
Al is generally more
expensive than
steel.
Low capital cost to
manufacture a suitable
metal returnable pack, with
little or no pack specific
equipment required.
Life of the pack likely to
rival a plastic equivalent.
Repair may be an option.
The disadvantages of metal in
this application are associated
largely with weight –
particularly for steel. With a
steel-based pack, the pack
weight could approach that of
the product, thus reducing
truck loading with a knock-on
environmental impact.
* Following EU implementation on 1 March 2005 of ISPM-15 (an international standard for phytosanitary measures developed by the International Plant Protection Convention), all
WPM such as boxes, crates, pallets made using any unmanufactured wood products must be either heat-treated or fumigated with methyl bromide under an officially approved
programme and carry the internationally agreed mark. WPM consisting entirely of manufactured wood products such as plywood, particleboard, oriented strand board or similar is
exempt, and need not be treated or marked.
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Appendix F: Project risk assessment
Significance Issue
Impact Risk
Mitigation
Access to retailer's staff and delivery chain.
High Low Obtain buy-in from retailer's senior management.
Access to manufacturer's staff. High Low Obtain buy-in from manufacturer's senior management.
Stakeholders not engaged in the project.
Medium Medium Ensure all interested parties represented in workshops and discussion groups.
Retailer's staff not happy with the new procedures.
Medium Low Ensure retailer's change management processes are fully engaged. Explain benefits to company and its staff.
Manufacturer's staff not happy with the new procedures.
Medium Low Ensure change management procedures are fully engaged. Explain benefits to company and its staff.
Difficulties integrating new packaging within retailer's and manufacturer's supply, storage and delivery procedures.
High Medium Study the current supply and delivery chain system. Utilise existing transport streams and logistics operations to minimise change.
Delivery team unhappy with new packaging.
High Low Develop design using UCD techniques, ensuring user participation within the design process. Make usability of packaging and associated packaging applicators a key factor in the design.
Customers concerned about new packaging.
High Low Address all functional requirements of packaging such as protecting from damage and breakages fully. Take customers’ views into account during design process. Market new delivery service as a benefit.
Suitable materials for packaging not found.
High Low Involve product design experts and sustainable design experts within project team. Research and obtain a full range of available materials and components.
Damaged to appliances increases as a result of the new packaging system.
High Low By its nature, reusable packaging is built to a higher specification than current packaging which is only used once. A key driver for the development of reusable packaging is to reduce the cost of ‘loss and returns’.
Low sales of appliances selected for trial leads to it being halted prematurely before conclusive results obtained.
High Low Select a product that is currently selling well and which is predicted to continue to sell well.
Packaging not returned by retailer's delivery crews.
High Medium The logistics aspect is fundamental to the success of this project. Focus attention on
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Significance Issue
Impact Risk
Mitigation
the human factors involved, engaging key personnel in the development of new procedures, training for delivery crews, internal marketing of project and change management. Incorporate simplification of the collection process into the design.
Packaging procedures not understood and/or valued by crews of third-party logistics company making manufacturer's deliveries.
Medium Low Include logistics company in development process. Ensure full awareness of new packaging and associated procedures.
Packaging lost within logistics system.
High Medium Change mindsets of packaging handlers and stock management to treat reusable packaging as a company asset, as part of the transport system and as ‘goods’ so that the RTS box will be registered as ‘goods in’ and will appear on all warehouse and stock management systems. Employ a tracking system.
Packaging damaged due to mistreatment within logistics system.
Medium Low Change mindset of logistics stakeholders so that packaging is treated as part of the transport system, with each package monitored and stored as goods to be returned to the manufacturer. Allocate storage space as for any valuable goods.
Appliance may reside with the customer in storage for some time before installation.
Medium Low Unpacking of product and removal of packaging will be part of the revised delivery service. The packaging will be part of the transport system.
Packaging does not meet current specifications.
High Low Perform the full range of tests normally applied to the manufacturer's products on the packaging, e.g. clamp tests, stacking tests, drop tests and inclined plane tests.
Not enough packaging is returned in time for the next batch run or build of appliances.
Medium Medium Compensate by allowing a contingency number of additional packaging units to be produced. Produce enough in advance for a set number of batch runs and allow time for return of packaging. Measure and monitor turn-around time, and adjust amounts required. Provide collection or storage pools at strategic locations.
Packaging supplier not familiar with specified material or specified design, or unable to source or work with specified material.
Medium Low Work with a supplier with a wide variety of products and services, and one open to innovative ideas and keen to be involved with new materials and designs. Consider
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Significance Issue
Impact Risk
Mitigation
involving other packaging suppliers.
Packaging left at customer location.
Medium Low Standard practice will be to unpack and take back RTS box. Consider either charge/fee if customer wishes to retain the box or supply alternative storage as cost item to customer.
Loss of packaging during delivery.
Medium Low to Medium
Employ tracking system to avoid loss.
No ownership of RTS box. Low Low Establish this at the outset.
Unfavourable business conditions at retailer and/or manufacturer prevent access to staff.
High Low Look for indications of this at outset. If necessary, locate other retail and/or manufacturing partners.
Lack of co-operation from manufacturer and/or retailer
High Low Ensure time and resources for engagement and activities have been at budgeted for. Appoint internal primary contact/project manager.
Lack of co-operation of third party logistics companies
High Medium Ensure time and resources for engagement and activities have been budgeted for. Use influence of manufacturer and retailer buying their services.
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Appendix G: Sales of large kitchen
appliances
UK
Table F1. Sales of selected large kitchen appliances in the UK, 2003-2008