Life cycle assessment of two baby food packaging alternatives: glass jars vs. plastic pots

This paper compares the life cycle assessment (LCA) of two packaging alternatives used for baby food produced by Nestlé: plastic pot and glass jar. The study considers the environmental impacts associated with packaging systems used to provide one baby food meal in France, Spain, and Germany in 2007. In addition, alternate logistical scenarios are considered which are independent of the two packaging options. The 200-g packaging size is selected as the basis for this study. Two other packaging sizes are assessed in the sensitivity analysis. Because results are intended to be disclosed to the public, this study underwent a critical review by an external panel of LCA experts. The LCA is performed in accordance to the international standards ISO 14040 and ISO 14044. The packaging systems include the packaging production, the product assembly, the preservation process, the distribution, and the packaging end-of-life. The production of the content (before preservation process), as well as the use phase are not taken into account as they are considered not to change when changing packaging. The inventory is based on data obtained from the baby food producer and the suppliers, data from the scientific literature, and data from the ecoinvent database. Special care is taken to implement a system expansion approach for end-of-life open and closed loop recycling and energy production (ISO 14044). A comprehensive impact assessment is performed using two life cycle impact assessment methodologies: IMPACT 2002+ and CML 2001. An extensive uncertainty analysis using Monte Carlo as well as an extensive sensitivity study are performed on the inventory and the reference flows, respectively. When looking at the impacts due to preservation process and packaging (considering identical distribution distances), we observe a small but significant environmental benefit of the plastic pot system over the glass jar system. Depending on the country, the impact is reduced by 14% to 27% for primary energy, 28% to 31% for global warming, 31% to 34% for respiratory inorganics, and 28% to 31% for terrestrial acidification/nutrification. The environmental benefit associated with the change in packaging mainly results from (a) production of plastic pot (including its end-of-life; 43% to 51% of total benefit), (b) lighter weight of packaging positively impacting transportation (20% to 35% of total benefit), and (c) new preservation process permitted by the plastic system (23% to 34% of total benefit). The jar or pot (including cap or lid, cluster, stretch film, and label) represents approximately half of the life cycle impacts, the logistics approximately one fourth, and the rest (especially on-site energy, tray, and hood) one fourth. The sensitivity analysis shows that assumptions made in the basic scenarios are rather conservative for plastic pots and that the conclusions for the 200-g packaging size also apply to other packaging sizes. The uncertainty analysis performed on the inventory for the German market situation shows that the plastic pot system has less impact than the glass jar system while considering similar distribution distances with a confidence level above 97% for most impact categories. There is opportunity for further improvement independent of the type of packaging used, such as by reducing distribution distances while still optimizing lot size. The validity of the main conclusions presented in this study is confirmed by results of both impact assessment methodologies IMPACT 2002+ and CML 2001. For identical transportation distances, the plastic pot system shows a small but significant reduction in environmental burden compared to the glass jar system. As food distribution plays an important role in the overall life cycle burdens and may vary between scenarios, it is important to avoid additional transportation of the packaged food in order to maintain or even improve the advantage of the plastic pot system. The present study focuses on the comparison of packaging systems and directly related consequences. It is recommended that further environmental optimization of the product also includes food manufacturing (before preservation process) and the supply chain of raw materials.