Microplastics: Rethinking packaging, manufacturing and storage

plastic bottles
Is it possible to reduce the amount of microplastics shed by bottles? Small changes can make a surprising difference (Image: Getty Images/montyrakusen)

Pack design and manufacturing methods can make a surprising difference

Microplastics and nanoplastics are an increasing concern to consumers. These are small plastic particles - invisible to the naked eye - than come from the degradation of plastics.

Research is increasingly showing their spread: with the particles found in marine species but also in drinking water and food.

And now a new study from Earth Action and rePurpose Global has looked specifically at their proliferation in food: finding that 1,000 tonnes of microplastic and nanoplastics move from plastic packaging into food and drinks every year.

PET bottles account for a third of total packaging related exposure: but particles also come from various types of plastic that come into contact with food.

Microplastics, nanoplastics and chemicals

It’s hard to single one plastic format out over another because it depends very much on how the pack is treated.

The design, the shape and the conditions it is kept under (such as heat or UV light) can all affect microplastic release.

And it’s not just about microplastics and nanoplastics: it’s also about the chemicals used in the material as well.

There are two main areas that affect exposure. There’s how consumers treat the package: whether it’s kept in a cool place or in hot conditions; whether it’s exposed to intense UV rays; or repeatedly put under pressure by crushing or squeezing. This is something brands and manufacturers have little control over.

But then there’s the manufacturing process itself, which they do.

Optimizing production processes

How much microplastic shedding comes from the manufacturing side compared to the consumer side is hard to answer, because it depends very much on the conditions in each.

But research shows that the microplastic load is already proportionally significant by the time a product reaches consumers.

“A lot of loss [of microplastics] happens even before the product enters the door,” said Dr Julien Boucher, co-CEO of Earth Action. “That could be during production, packaging, processing, or storage or delivery.”

So what can brands do? Looking at the design of a plastic bottle is one key step: with the bottle and cap and friction being a source of shedding. Continuous rings typically generate less microplastics than segmented ones.

Bigger pack formats will typically be responsible for less microplastics proportionally.

And how well a package handles mechanical stress is another factor.

And manufacturers can also think about the rest of the supply chain. “Producers can influence - even if not directly control - how packs are stored and delivered,” he says. “You provide information to the key stakeholders to try and avoid the worst-case scenarios.”

Assessing the hot spots

Boucher’s main message is that companies can take action to reduce microplastics - and it can be surprisingly easy.

“Our report shows that emissions can go up very easily and very quickly if you don’t make the right decisions,” he said.

“There are solutions in terms of design and in the supply chain that can make a big difference.”

Companies can use Earth Action’s resources to assess their own operations and calculate where the hotspots are: and plan action to lower emissions.

“I hope our report will drive decisions and management. The message is that we have some solutions to improve,” he said.