Water Soluble Film for Home Care An IHPCIA Initiative 2 Industry - - PowerPoint PPT Presentation

Concentrated Laundry Detergents in Water Soluble Film for Home Care

An IHPCIA Initiative

1 November 30, 2018

Save Water Save Energy Save CO2 Save Packaging

Industry Vision–Harmony with Nature

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An IHPCIA Initiative

Factors affecting Home Care Sector

• Lifestyle Changes
• Stressed environment
• Multi Polar World
• Digital Technology

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Water Stressed World

Experts predict a near crisis water situation in coming years 4

Plastics Pollution in Ocean

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Plastics Pollution in Ocean & Solutions

• Plastics in the ocean contributed to 8 mn tons in 2012 and this has gone

upto 12.7mn tons in 2018

• Greenhouses gases have gone up by 17.5% during the same period of six

years. What are the solutions? Moving away from single use plastics and looking at the ban imposed on the use of plastics the only option is to look at alternatives that can save water, energy and efficiency

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Sustainable Consumption and Production and the Role of Green Products in India

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Changing Consumer Preferences

• Consumers are now looking at value for the products that

comes through the design of the products. There is growing emergence of preference for regional players 'products

• In the multi polar world there are disruptive trends and hence

there are opportunities.

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Living Differently

• I want what I want when I want it
• Growth by population and income is no more valid
• More people are preferring outsourcing of laundry
• Digital Technology Revolution – Smart homes of the future
• Consumers want personalised solutions and smart

production.

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Smart Production

• With focus on concentrated liquids and out of foam

technology.

• Increased focus on biotechnology. Use of green surfactants –

plant based, sugar based and algae based.

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Technology Innovations-Key to achieving cleaner products and sustainable growth

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Impact:

1. CO2 Imprints 2. Reduce Water Consumption 3. Reduce Energy 4. Biodegradability

Sustainability via the Bio based economy and Monodose

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• Sustainability marketing strategies should aim towards improving the awareness of
• Consumers to use the product in an informed / sustainable way
• Existing Mechanisms such as Eco labels and safe use tips provided on the pack are confusing

consumers believe that there is insufficient or too much information provided

• Monodose is the sustainable option.

Actions needed (non technological) to improve the sustainability profile of the industry

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Need for Sustainability in the Industry

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A Sustainable Solution Concentrated Laundry Detergent (CLD) in WSF

• Product innovation has been one of the major influences in reducing the

environmental impact of laundry detergent. Sustainable consumption of detergents has been promoted by linking it to other benefits which consumers find more important. CLD in WSF can do that by:-

• Offering products that use natural ingredients derived from renewable sources
• Eliminating use of minerals, fillers, phosphates and zeolites
• Making products in concentrated form
• Use of water soluble films (polyvinyl alcohol)

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A Sustainable Solution Concentrated Laundry Detergent (CLD) in WSF –contd.

• CLD products has seen enthusiastic response from customers in several markets

where it has been introduced so far and has garnered 17% market share in the US in just five years thanks to its benefits of consumer convenience and precise dosing.

• The Indian market is ready to take on this novel product as several factors are in

favour: ban on multi-layer packaging; space constraints in urban homes; stressed water availability; greater number of women in the workforce and hence demand for more convenient products etc. 15

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Why CLD in Water Soluble Films (WSF)?

Precise dosing (no over- or under-dosing) Consumer convenience (no measuring, easy to use) Separation of ingredients via multi- compartment designs

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Save The Planet!

• Reduces Shipping Cost
• Lower Water Shipped
• Reduces use of plastic packaging
• Lower energy consumption
• Cold water wash
• 100% Biodegradable
• CO2 imprint significant

Bulk Detergents CLD-WSF

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Indian Scenario

• 15 thousand tons of detergent powders consume 15mn plastic

bags per day

• IHPCIA aim is to facilitate reduction of use of plastics @10%

per year with 2022 target of reaching 40% reduction of plastics

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USA France United Kingdom Japan Spain Canada Italy Belgium Germany Switzerland Other

500 1,000 1,500 2,000 2,500 3,000

2014 2015 2016

Global Laundry Market

52% 51% Powder 51% 7% 8% Std. liquid 9% 34% 34% Conc. liquid 34% 6% 7% Unit dose 7%

• 5,000

10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 2014 2015 2016

Share by Category (Retail Value) Unit Dose by Country (Retail Value)

5% 11% 12% Unit: Mil USD Unit: Mil USD

• Global SUD market rapidly growing: 21% CAGR (2012-2016)
• Monodose market growing at 11% (vs. 5% for overall detergent) in 2016
• Potential for geographic expansion in India by leap of technology

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Indian Detergent Market Landscape

 Current Market Size (Organized Detergent Market)- USD 2.21(Billions)  Total Volume (Production) : 2.5 Million Tones  CAGR(2012 -2016): 10% approx.  Washing Machine Penetration in India:9 %  Indian Population Division: Urban: 33% Rural : 67%  Households Owing Washing Machine: Urban: 27.5% of all Urban households

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Comparison of Formulations Detergent Powders Vs CLD in WSF Pouch

Contents Detergent Powder Monodose Popular (1kg) Premier (1kg) Liquid pouch Dosage 100 gm Dosage 65 gm 25 ml/dose Actives % 12 20 65 LABSA 12 LABSA 10 Naturals+ SLS/SLES 5 NI+PG +Enzymes+ Polymers 15 AOS/NI 5 Solvent Fillers/Soda Ash % 60 20 NIL Salt/Sulphate % 10 25 NIL Talc/Bentonite % 5 NIL Performance Enhancers % NIL 10 2 Polymers % 1 3 1 Enzymes % nil 2 2 Moisture % 10 5 5 Packaging Poly bag Multi-layer bag PVA film

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What does CLD packed in WSF pouch do?

Laundry Detergent CLD

Automatic Dishwasher CLD

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Next Generation Films

POWDERS POWDERS (AG CHEM) LIQUID LAUNDRY MULTI-COMPARTMENT LIQUID LAUNDRY CHILD SAFETY COMPLIANCE 1961 1991 1999 2012 2015 2018

Evolution enabled by Innovation

INNOVATION

• Low residue
• High thermal formability

(Pouch design flexibility)

• Added functionality
• Enhanced compatibility
• Enhanced machine

handling

• New applications

(Personal care, etc)

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Evolution enabled by Innovation (Contd.)

• Bulk Sized Packs
• Machine Dispensers e.g. Cleanyst Dispensers

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Development of CLD in WSF in India

• Films Selection
• Formulation Development
• Equipment supplier
• Co-packer

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Detergent Formulation

• High concentration
• Single or multi chamber
• Liquid / Powder

combination Conversion Equipment

• Line speed
• Sealing method
• Single/multi chamber
• Cavity shape/design

Water Soluble Film

• Dissolution
• Chemical resistance
• Physical properties
• Compatibility testing

Coordinated Product Development

Developing CLD Products

PROCESS ABILITY

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PVOH Film Compatibility

• Further hydrolysis of residual acetate (pH effect)

− Special film grades are required for formulations with high (alkaline) and low (acid) pH – above 8 and below 5.

• Crosslinking

− Includes gelation (i.e. boron compounds) − Esterification (i.e. polycarboxylic acids) − Intermolecular dehydration

• Formation of acetic acid from sodium acetate
• Oxidation (eg., by Cl2)
• Reverse salting out effect (by salts/ionic strength)
• Inhibition of film solubility in salt solutions
• Inhibition of film solubility when salts partially dissolve into film
• Reactions on hydroxyl by reactive functional groups

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Ingredient Incompatibility

Chemical Examples Water Maximum of 10 wt% free water recommended Tri- and tetra- amine Diethylene triamine, and triethylene tetramine Boron containing compounds Sodium perborate, borax Inorganic and organic halogenated compounds Inorganic chlorine* compounds Strong oxidizing agents including halogenated compounds Persulfates, percarbonates (may be tolerated with limited moisture ingress) Phosphates Sodium tripolyphosphate, tetrasodium pyrophosphate Di- and tri-carboxylic acids* Citric acid, oxalic acid, maleic acid Dialdehydes* Glutaraldehyde, glyoxal Monoaldehydes under acidic conditions* Often present in fragrances especially floral Cupric salts Zinc, aluminum, titanium, vanadium, chomium salts, or esters Ionizing Soluble Salts (Inhibits solubility of PVOH film) Sodium sulfate at approx 5 wt %

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Physical Compatibility: Plasticization of film and/or moisture loss causing embrittlement

Examples

All hygroscopic solids Clays (bentonite, kaolin, etc), diatomaceous earth Microporous Materials, Zeolites, aluminosilicates, aluminophosphates Quaternary Ammonium Compounds

Examples

All hygroscopic liquids Many organic solvents, especially aliphatic solvents and lower alcohols Most glycols (glycerin, propylene glycol, diethylene glycol) Max of 20 wt% recommended Ethanolamines

• Solid Formulations
• Liquid Formulations

Ingredient Incompatibility

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CLD example

Family Type Typical Range Surfactants (Anionic, Cationic, non-ionic) diethanolamine, triethanolamine, monoethanolamine, etc. 45-70 % Base/Builder Oleic Acid 18-23 % Solvents Propylene Glycol, Diethylene Glycol, Glycerin, etc. 18-23% Water

• 3-10%

Fragrances Free + PMC 0.1-1.5% Enzymes Amylase, Cellulase, Lipase, etc 0.2-0.5% Optical Brightners, Sequestrants

• ther

0.2-2%

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Water Soluble Film Converting Options

MonoSol has strong relationships with equipment manufacturers and contract packers to support water soluble film conversion.

• Rotary Drum – PVA continuous motion drum technology is

used to form water soluble materials (polyvinyl alcohol) at speeds of up to 2400 packages per minute.

• Flat-bed intermittent line
• Vertical Fill Form Seal – VFFS
• Pleat wrapping compressed tablets

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Rotary Drum

• High speed, high capacity
• Top-line
• 40 million pouches/year
• Cost: $500k-1.2 MM
• Options dictate cost: Powder,

liquid, chambers, output

• Additional costs: packing lines,

environmental controls

• Typical payback: 18 months

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Secondary Packaging

• Require appropriate secondary / outer

package to keep moisture in and out.

• Suggested options include stand up pouch &

injection molded

• r

thermoformed tubs/containers/jars using commonly available polymers such as PP, HDPE, PET etc.

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RDM Investment Model

INPUT

Machine Cost & Parameters: Film Inputs & Cost:

Select Machine Type RDM 165 Liquid Select Choose Film Type M8720 Select Choose Film Thickness Application -Powder / Liquid Liquid Top 3.0 Select Bottom 3.0 Select Cost of Machine $ 470,000 Additional Machine Costs $ 80,000 Cost of Film per kg $ 18 Machine Running Hours (Daily) 16 Machine Run Days Per Month 24 Labor Cost: Packaging: # of Employees 6 Type of Secondary Packaging Standup Bag Select Pay per Hour $ 1.00 Count per Finish Package 30 Formulation: Pouch Costs: Formulation Type Liquid Price per Pouch $ 0.15 Estimated Cost of Formulation / Pod $ 0.06 Cost per Pouch $ 0.10 Selling Price: Selling price / finished pack $ 4.50

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OUTPUT

Running Cost Breakdown

% of Run Cost Cost of Film $ 1,054,280 22% Cost of Formulation $ 2,900,670 61% Cost of secondary Packaging $ 241,723 5% Cost of Conversion $ 569,849 12%

Machine Payback:

Investment Cost $550,000 Running Cost $4,766,522 Total Unit Output per Year 48,344,503 Total Finished Packages 1,611,483 Estimated Investment recovery time (months) 32

Return on Investment Total Revenue per Year $ 7,251,675 Total Running Cost per Year $ 4,766,522 Total Profit per Year $ 2,485,154 * Run Waste : Side trim included in calculation

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Implementation

• Formulation development
• Design development
• Equipment acquisition and installation
• Film selection and supply establishment

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Timeline

• Formulation and Film development/selection: 6-12 months if

new; lesser if current

• Equipment: 6-8 months
• Film supply: 2-4 months
• Secondary packaging design and development: 3-6 months

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Safety Measures: CLD in Unit Dose

Aversive agent in film Compressive strength of SUD > 300 N SUD retains detergent liquid for ≥ 30 s in water (20°C) 38

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Safety Measures: Outer Packaging

Child-impeding re-closable closure Needs coordinated action of both hands On-pack labeling using attention-grabbing icons Opaque container 39

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• For this we have been working on different aspects throughout the

process, either its related to changing structural parameters of packaging material or even if it is linked to upgrading packing machinery.

Initiatives Taken By RSPL In Plastics Reduction

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Initiatives Taken For Reducing Plastic Consumption In Primary Packaging Material

• UPGRADING PACKING MACHINES

By upgrading our finished goods packing machines we have been able to reduce packaging material wastage up to 5-6% of our total consumption which is approximately 150 MT. of packaging material saving per annum, and we are continuously working on it further to minimize it as much possible.

• For bulk detergent pack we have introduced new style of packing, that

helped us to reduce the packaging material wastage up to 3% - 4% which is approximately 30 MT. per annum and has been reduced to nil.

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• REDUCING PACKAGING MATERIAL THICKNESS

We have worked on our packaging material quality that could help

us to reduce plastic consumption, for which we took an initiative to reduce the thickness of the packaging material from 15 % to 25% without compromising with the packing quality. The overall

• utcome of this initiative was that we achieved to reduce our

plastic consumption up to 2000 MT. per annum.

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• REDUCING PACKAGING MATERIAL THICKNESS

As similar to primary packaging material quality working the same concept was introduced for our secondary packaging material also and after working on the same we reduced the thickness of our secondary packaging material from 25 % to 30%, and this initiative helped us in achieving to reduce our plastic consumption up to 500 MT. per annum. INITIATIVES TAKEN FOR REDUCING PLASTIC CONSUMPTION IN SECONDARY PACKAGING MATERIAL

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• Overall reduction in plastic consumption through primary

packaging material is approximately 2180 MT per annum.

• Overall reduction in plastic consumption through secondary

packaging material is approximately 500 MT per annum.

• As we are continuously working on further in the field and we

have targeted to reduce packaging material & process wastage up to 1000 MT. to 1200 MT. in next 5 years with addition to the numbers that we have already achieved .

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THANK YOU

• Mr. Sanjay Trivedi

Director Indian Home & Personal Care Industry Association Tel: +91 22 2877 1857 Fax: +91 22 2874 1366 Email : strivedi@ihpcia.org URL: www.ihpcia.org