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In GREENZERO Journey, packaging is a critical component of product management that significantly contributes to a product’s overall environmental impact. Packaging serves multiple functions—protecting products during transport, providing information to consumers, enabling efficient storage and handling, and often playing a role in marketing. From an LCA perspective, packaging requires careful consideration as it can represent a substantial portion of a product’s total environmental footprint.

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Packaging Hierarchy

Packaging is typically categorized into three hierarchical levels, each serving different purposes in the product’s journey from manufacturer to end user:
Primary packaging is the layer that directly contains the product and is what consumers typically interact with first. It’s the packaging that remains with the product until it’s used or consumed.Examples of Primary Packaging:
  • Glass bottle containing a beverage
  • Plastic tube holding toothpaste
  • Cardboard box containing cereal
  • Blister pack holding tablets or capsules
  • Paper wrapper around a chocolate bar
  • Aluminum can containing soda
  • Plastic pouch holding coffee beans
Primary packaging often has the most stringent requirements for material compatibility with the product, barrier properties, and consumer interaction.
Secondary packaging contains one or more items in primary packaging. It typically serves to group products for retail display, provide additional protection during transport, or offer marketing opportunities.Examples of Secondary Packaging:
  • Cardboard box holding multiple bottles of shampoo
  • Shrink wrap bundling multiple cans of soda
  • Display carton containing individually wrapped chocolate bars
  • Corrugated tray for multiple jars
  • Paperboard sleeve around a group of yogurt cups
  • Plastic ring carrier for beverage cans
  • Gift box containing a perfume bottle and accessories
Secondary packaging is often removed and discarded at the retail level or by consumers before product use.
Tertiary packaging is used for bulk handling, warehouse storage, and shipping. It’s designed to protect products during transportation and facilitate efficient logistics operations.Examples of Tertiary Packaging:
  • Wooden pallets for stacking and moving goods
  • Stretch wrap securing products to pallets
  • Large corrugated shipping containers
  • Plastic or metal strapping to secure loads
  • Slip sheets for forklift handling
  • Corner protectors for fragile shipments
  • Bulk containers and intermediate bulk containers (IBCs)
Tertiary packaging typically doesn’t reach the end consumer and is managed within the supply chain.
Currently, GREENZERO Journey only supports primary packaging in its LCA calculations. Secondary and tertiary packaging support is planned for future releases. For comprehensive packaging impact assessment, please focus on accurately documenting primary packaging components.

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Packaging as a Bill of Materials (BOM) Element

In GREENZERO Journey, packaging is managed using the same fundamental structure as any other Bill of Materials (BOM) element. This means that each packaging component:

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Has Its Own Supply Chain

Each packaging material can have:
  • Separate Suppliers: Different vendors may provide various packaging components
  • Different Manufacturing Processes: Each packaging element may undergo distinct production methods
  • Unique Transport Routes: Packaging materials may travel different paths to reach assembly locations

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Maintains Individual Properties

Like other BOM elements, packaging components have their own:
  • Weight: Specified in appropriate units (typically grams or kilograms)
  • Quantity: Number of units per product
  • Material Composition: Specific materials used (e.g., PET, HDPE, cardboard, glass)
  • Dimensions: Size specifications relevant for transport and storage calculations

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Generates Distinct Impact Results

The system calculates and reports:
  • Individual environmental impacts for each packaging component
  • Contribution of packaging to the product’s overall impact
  • Specific impact category results (GWP, water use, etc.) for packaging elements
  • Opportunities for packaging optimization and improvement

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Packaging Management in GREENZERO Journey

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Creating and Editing Packaging

Packaging can be managed through the Product Management interface by:
  1. Navigating to a product’s detail page
  2. Selecting the “Packaging” tab
  3. Adding or editing packaging components
  4. Specifying materials, weights, quantities, and other relevant properties
  5. Assigning suppliers and manufacturing information when available

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Packaging Analysis

GREENZERO Journey provides specific insights for packaging, including:
  • Packaging-to-product weight ratio analysis
  • Material efficiency assessments
  • Recyclability and end-of-life evaluations
  • Comparison with industry benchmarks for similar products
  • Improvement recommendations specific to packaging

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Packaging Optimization

The system can suggest packaging improvements such as:
  • Material substitutions with lower environmental impact
  • Weight reduction opportunities
  • Design changes to improve recyclability
  • Alternative packaging formats with better overall performance
  • Supplier changes based on environmental criteria

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Best Practices for Packaging Documentation

To get the most accurate LCA results for packaging in GREENZERO Journey:
  1. Be Precise with Weights: Even small differences in packaging weight can significantly affect results
  2. Specify Exact Materials: Use specific material types rather than general categories
  3. Include All Components: Document all primary packaging elements, including labels, caps, etc.
  4. Update Regularly: Keep packaging information current as designs change
  5. Provide Supplier Information: When possible, include specific supplier data for more accurate results
By treating packaging as an integral part of the product’s Bill of Materials, GREENZERO Journey enables comprehensive environmental impact assessment and targeted improvement strategies for this critical aspect of product design.
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