Sustainable Redesign of Plastic Packaging: Transition Single-Layer for Enhanced Efficiency and Circular Economy
Abstract
The flexible packaging industry faces increasing demand to balance product functionality with environmental sustainability. This study focuses on redesigning plastic packaging by transitioning from dual to single-layer structures. The six-phase product development methodology was employed to assess this transition's technical and economic impacts. The findings show that the single-layer design reduces raw material usage by 20%, lowers production costs by 7.5%, and shortens production time by 780 minutes per 8,000 meters of packaging. Although slight increases in Water Vapor Transmission Rate (WVTR) and Oxygen Transmission Rate (O2TR) were observed, the changes remained within acceptable industry standards, with minimal impact on product shelf life. The new design also offers significant environmental advantages, simplifying recycling processes and supporting circular economy principles. Furthermore, the House of Quality (HoQ) analysis revealed that the redesign effectively addresses critical customer needs, particularly regarding durability, affordability, and delivery efficiency. This research demonstrates the potential for sustainable innovation in the packaging industry. It provides a pathway for companies seeking to reduce environmental impacts while maintaining product performance.
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