5 Ways Eco Friendly Packaging Impacts Material Handling

As more people become concerned with environmental protections, companies are changing their packaging. Packaging with sustainable, recyclable materials are becoming more popular and common across many companies. 
 
But that change means material handling processes need to be updated.

Why Does Eco Friendly Packaging Needs Different Processes? 

Different materials are used in eco friendly packaging compared to traditional packaging. These materials have different lifting considerations that operations must address.  

Companies should adapt their material handling processes to meet the new demands of sustainable packaging materials. 

What Industries Are Using It? 

Sustainable packaging is becoming more common and used across many different industries. Here are a few industry-specific examples: 

Food & Beverage 

• Ultra-thin OPP / BOPP film bags for crisps, crackers, etc. 
• Cardboard cartons for biscuits, crackers, etc. 
• Gusseted PE / PP pillow bags for baked goods, snacks, coffee, etc. 

Consumer Goods 

• Refillable pouches for cleaning products like dish soap or surface cleaner 
• Lightweight HDPE / PET bottles for detergents, household cleaners, etc. 
• Lightweight board cartons for cosmetics and OTC products 

Logistics 

• Recycled corrugated boxes 
• Bio-based stretch/shrink film to stabilise pallets 
• Paper shipping bags 

Pharma & Medical 

• Blister packs with thin PVC / PVDC or Aclar films 
• Low-basis-weight board for over-cartons that contain vials, syringes, etc. 
• Sterile wraps or bags in thin nonwoven or film materials 

Electronics 

• Lightweight folding cartons for devices or accessories 
• Molded paper pulp inserts to cushion electronics 

 

How Does Eco Friendly Packaging Affect Material Handling Processes? 

The material being lifted affects how you should lift it. Let’s explore five material handling considerations for sustainable packaging. 

1) Handle with Care 

Sustainable packaging (like films, bags, or cartons) can be made with lighter materials. These thinner materials can tear or become crushed more easily.  

To keep product quality intact, items need to be handled with precision and care. Controlled, gentle lifting reduces scrap, rework, and returns. Also, maintaining product integrity supports ESG goals because there is less waste and better use of resources. 

2) Distribution of Weight 

With thinner, fragile materials, it is also important to consider how to spread the load. If a worker puts too much weight on one part of the packaging, they could break or damage it.  

When lifting, spread out the weight to avoid having too much pressure at one point.

3) Quick Changeover 

More diverse packaging types means that operations need to changeover between SKUs more often. If the changeover is inefficient, operations will slow down. This makes material handling a bottleneck that hurts production goals. 

Looking for ways to accomplish quick changeover speed is important for operations. No matter the material being lifted (paper bags, recycled cartons, pouches, etc.), workers need a process that allows them to effectively change SKUs. 

4) Production Volume 

Many companies want workers to handle greater volumes of materials to increase production. While sustainable packaging can be lighter than traditional, they can still be bulky. 

Bulky materials are cumbersome to lift. Also, repetitive lifting motions puts physical strain on workers, even when lifting lighter items. Using lifting equipment to handle the weight of the load makes processes more sustainable for your staff. 

5) Cleanliness Standards 

Sustainability packaging often leads to the use of more paper and recycled paper. This creates more dust and debris for operations. 

Facilities need a process to clean packaging areas and equipment. Also, equipment must be able to operate and be maintained in a dusty environment. 

 

Explore Effective Lifting Tools for Eco Friendly Packaging 

Manual lifting makes it challenging to handle sustainable packaging gently, safely, and efficiently. It can be beneficial to explore ergonomic lifting solutions. These solutions ensure consistent lifting throughout the day and damage-free handling. 

How Do Lifting Solutions Help Improve Material Handling? 

Lift assists can help address the main material handling concerns of sustainable packaging. 

• Careful lifting & positioning: Lift assists manage a gentle, yet firm grip on products. Products stay safe during lifting, moving, or rotating. 
• Spread the load: Suction feet on vacuum lifters can grip a product in multiple places to handle the weight of items safely. 
• Quickly lift different materials: Vacuum lifters have quick disconnect suction feet, so one lifter can be used to lift different kinds of items like boxes, bags, etc. 
• Consistent speed: Humans get tired but lift assists don’t. They can maintain a consistent speed throughout a shift, so operations can achieve their production goals. 
• Dusty environment: Lift assists can work in dusty environments. For example, vacuum lifters have a dust filter to protect the machine.  

What are Specific Situations to Consider Using Lifting Solutions? 

The type of item affects how it should be lifted and what equipment to use. For eco friendly packaging, materials commonly come in reel, sack, or box formats. 

Reel Handling Examples 

• Lift a film reel from the outside or from the core with a lifting trolley 
• Move a reel off or onto a packaging spindle 
• Rotate a reel so it's in the proper placement 
• Explore reel handling applications  

Sack Handling Examples 

• Move a paper sack with a vacuum lifter 
• Lift a jute sack with a specifically designed suction foot 
• Explore sack handling applications  

Box Handling Examples 

• Move a recyclable box from a conveyor to a pallet with a vacuum lifter 
• Unload boxes from a truck with a container unloader 
• Transport boxes around a warehouse with a mobile vacuum solution 
• Explore boxes handling applications  

 

Stay Adaptable to Operational Changes 

As packaging continues to change, operations have to adapt. That’s possible with lifting systems in place that can adapt to new changes.  

While workers can adapt to lifting different items, there are physical limitations and safety concerns. That’s why it’s recommended to use flexible lifting tools to keep people and products safe. 

To learn more about current operational realities facing packaging operations, read our challenges, trends, & best practices article. 

To work with a lifting expert and discuss your packaging needs, contact us. We would be happy to help with your application.