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LNK International

LNK Intenational and Disc Graphics, Inc implementing Eco-Friendly Solutions
Supply chain collaboration yields eco-friendly/cost effective solutions

LNK International is one of the world’s largest suppliers of Private Label OTC aspirin, pain relievers, cough and cold remedies.
  • Established in 1980.
  • Annual Revenues exceed $100 million.
  • LNK International is registered with U.S Food and Drug Administration, N.Y. State Board of Pharmacy and the U.S. Drug Enforcement Administration as a manufacturer and distributor of over the counter pharmaceuticals.
Disc Graphics is a nationally recognized leader in the printing and packaging industry
  • Established in 1983.
  • Annual Revenues of approximately $50 million.
  • Recognized as “Best of the Best” workplaces in America by the PIA.
  • The company’s DISCover Green program has yielded significant eco-solutions for its customers.

Background

According to the EPA, Source Reduction and Reuse are highly effective and preferred
methods to stop or minimize waste from entering into the solid-waste-stream.i

lnk design

In reviewing their options, LNK International and their supply chain partner
Disc Graphics felt the greatest opportunity to reduce waste, develop environmentally
friendly alternatives and have the potential to save money was through source reduction
and reuse.

Eco-Opportunity: OTC Pharmaceutical Folding Cartons

Change the folding carton packaging to achieve a reduction in greenhouse gases, while reducing costs. The change cannot significantly alter the performance characteristics or aesthetics of the carton.

lnk opportunity

Solution: Source Reduction

Source Reduction is part of a design strategy and is imbedded in the Disc Graphics package-design-review process. The EPA defines Source Reduction as “any change in the design, manufacture, purchase, or use of materials or products (including packaging) to reduce their amount or toxicity before they become municipal solid waste. Source reduction also refers to the reuse of products or materials”.ii In considering the environmental aspects of the design Disc provided a life-cycle assessment, alternative materials analysis, looked at preferred means to reach “waste-minimization-objectives” and affect sustainable design. However, as illustrated in the graphic below, environmental design ideas are balanced with other aspects in a holistic approach to design strategy.

Package Design Review

lnk design


After conducting a design review, which included testing various recycled substrates and non-paperboard alternatives, the companies concluded that converting the paperboard folding cartons from 16 pt. to 15 pt. SBS provided the greatest economic and environmental return while maintaining the brand, value perception, security, and performance characteristics of the carton.

Benefits

  • Saved 175 Tons of paperboard in first year.
  • 307.4 Metric Tons of Carbon saved based on fewer trees cut down.
  • The change mitigates the impact of rising paper costs.
  • Extensive testing proved the change to 15 pt. met the performance requirement of the carton.

Eco-Opportunity: Single Use Corrugated Shippers

LNK and Disc Graphics through collaboration on green initiatives both recognized the waste created by using single-shipment corrugated containers. The delivery of folding cartons in corrugated shippers is a standard practice in most supply chains. Once used the corrugated is collapsed and generally palletized for shipment to a recycler.

Project Evaluation

lnk background
Disc Graphics and LNK examined such factors as the potential lifecycle of reusable shippers, environmental impact, ROI, managing a closed loop system for return and use of shippers, and environmental metrics.

Solution: Reusable Supply Chain Packaging

Corrugated shipping containers are so named for the fluted inner layer that is sandwiched between layers of linerboard. Such containers are readily available, provide impact and drop resistance, while still being light weight. However, they are generally single use and are a major contributor to the solid waste stream.

CORRUGATED BOXES MUNICIPAL SOLID WASTE (MSW) FACTS iii

Generated:
  • 31.4 million tons and 12.5% of the national solid waste stream by weight.
  • 210 pounds per person per year.
  • 32.6 million tons in 2007 according to industry data.
Recycled:
  • 22.6 million tons, for a 72.0% recycling rate.
  • 25.6 million tons (78.3%) in 2007 according to industry data.
Based on the review of several environmental studies, the use of multi-delivery shipping cartons showed significant environmental benefits. As an example, reusing single multi-delivery container 20-times would save 40 pounds of solid waste based on an average 2-pound one-way corrugated container. Total use just for the LNK shipments, can yield an approximate potential saving of several hundred thousand pounds of waste per year. Even though the corrugated shipping containers are recyclable, it still takes energy to transport the used containers, and to re-pulp and convert it back into a usable form. Since proximity and the ability to create a closed loop process is within reach, Disc and LNK developed a pilot program. Although early in the program, it has achieved expectations and it seems clear that a larger scale program will be implemented in the near future.

lnk solution

Benefits

  • Corrugated Polypropylene is widely accepted as having the least environmental risk of all the plastic resins.
  • Multi-trip containers can at a minimum reduce solid waste, save energy and cost to recycle, reduce handling and storage of waste corrugated.
  • According to recent studies the substitution of reusable containers for single-use corrugate shipping containers reduced green house gas emissions by 39%.iv

Conclusion:
Collaboration is essential to achieve sustainable eco-friendly solutions

To achieve your eco-objectives it is important to first look at opportunities to eliminate or reduce the potential waste created by your processes or supply chain. Although many packaging designers look at alternative materials, try beginning with putting less into your package. Source reduction is the preferred method to reduce waste. In addition, review the supply chain and look for change opportunities that are often overlooked because they are considered standard industry practices. Making eco-decisions requires the willingness to open conversations about something as common as corrugated containers and ask how we can manage this process differently that will reduce waste and save money. This case study also illustrates that supplier partnerships are key to achieving your eco-objectives. Expand your resources by including suppliers with proven track records using eco-design criteria. Remember, not all environmental alternatives cost more, and in today’s economic environment making your processes greener without spending fields of it is the ultimate goal.


i - Saphire, D., (1994). Delivering the goods: Benefits of reusable shipping containers. New York: Inform, Inc. (Inform, Inc. is an NGO focused on business and municipal practices).

ii - EPA, February 18th, (2009). Waste-Resource Conservation- Reduce, Reuse, Recycle. Retrieved March 11, 2009 from http://www.epa.gov/epawaste/conserve/rrr/reduce.htm

iii - Miller, C., (2008). Corrugated Boxes: Corrugated boxes are the biggest component of the waste stream by weight. Retrieved March 12, 2009 from http://wasteage.com

iv - Franklin Associates, (2004). Life Cycle inventory of reusable plastic containers and display-ready corrugated containers used for fresh produce applications, presented to the reusable pallet and container coalition. Cited by the Orbis Corporation, 2007.
 
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Disc Graphics Inc | 10 Gilpin Ave | Hauppauge, NY 11788 | (631) 234-1400