Sustainable recycling of containers and packaging

Sustainable recycling of containers and packaging

Containers and packaging are essential to protect the quality of products for delivery to our customers. To address the issues caused by containers and packaging, the entire industry has promoted 3R (reduce, reuse, recycle) and achieved a high recycling rate.
In March 2021, the Kirin Group joined the Alliance To End Plastic Waste (AEPW), an international non-profit organization, in order to solve problems related to waste plastic in the world from a global perspective, together with other participating companies. In cooperation with global companies, organizations, and other entities involved in the plastic value chain that participate in AEPW, we are promoting projects in four strategic areas: “infrastructure creation and development,” “innovation,” “education and awareness-raising activities,” and “clean-up activities.”

• The Forest Stewardship Council® (FSC) Forest Certification System is a system for the appropriate management of forests and the sustainable use and conservation of forest resources. The FSC label is a mark that protects forests.

Targets

Sustainable recycling of PET bottles

R100 PET bottles

In accordance with the Plastic Policy that we established in 2019, the Kirin Group is gradually expanding the use of “R100 PET bottles” made from 100% recycled PET resin.
“R100 PET bottles” use “mechanical recycling” technology to enable the use of recycled PET material as a raw material for PET bottles. These bottles use 90% less resin derived from petroleum and achieves a reduction in GHG emissions of 50-60% compared with regular petroleum-derived PET materials.
We began using recycled resin for some of the packaging of Kirin Gogo-no-Kocha Oishii Muto (sugar-free) product in February 2014. Subsequently, in 2019, we began using “R100 PET bottles,” which use 100% recycled PET resin, for Kirin Nama-cha Decaf, followed by Kirin Nama-cha and Kirin Nama-cha Hoji Sencha (600ml size for each), which are only available in convenience stores throughout Japan, from 2021. We also began using “R100 PET bottles” for Kirin Nama-cha Life Plus Immune System Assist from October 2021, and Kirin Nama-cha Caffeine Zero in April 2022, and we have since continued its use in these products.

chemical recycling

In December 2020, Kirin began technical studies and a joint project aimed at commercialization with Mitsubishi Chemical Corporation Corporation, focusing on recycling PET bottles using chemical recycling.
In the current mechanical recycling system, there are impurities that are difficult to remove from recycled resins, and it is said that the quality of resins deteriorates with repeated recycling. In chemical recycling, we sort, crush, and wash used PET bottles to remove dirt and contaminants, then we depolymerize them (chemical decomposition treatment), and break down and purify the PET into intermediate raw materials, which we then polymerize (synthesize) again into PET. It is possible to recycle PET bottles to a state similar to new materials as many times as we want through decomposition down to the molecular level, and we can also recycle PET products other than used PET bottles into PET bottles. In addition to aiming to establish a circular economy for PET products, we will also build a system for collecting PET products other than PET bottles. Since 2022, we have been working with FANCL to promote the reuse of PET materials.

Promotion of more efficient sorting, collection, and recovery

Aiming to create “a society that continuously recycles plastics,” in July 2021, we launched a demonstration trial to collect used PET bottle containers, in collaboration with Lawson, Inc. In June 2022, we also expanded the demonstration to Welcia Yakkyoku Co., Ltd.
In the demonstration trial at WELCIA, we collect and sort used PET bottles in collection boxes installed at WELCIA stores, and after gathering these materials at a WELCIA distribution center, we transport them to Far Eastern Ishizuka Green PET Corporation, a recycler.

*Product photos are as of the end of June 2022.

Initiatives for sustainable paper containers

At the end of November 2020, the Kirin Group achieved the 100% use of FSC-certified paper in all paper containers and packaging at Kirin Brewery, Kirin Beverage, and Mercian. The targeted paper containers are “6-can packs,” “gift boxes,” “drink boxes,” and “cardboard cartons.” This is the first declaration and achievement of that declaration by a Japanese manufacturer to cover all paper containers.
In 2022, we revised the “Action Plan for the Sustainable Use of Biological Resources,” and expanded the scope of Group companies to include Kyowa Kirin, Kyowa Hakko Bio, Lion, and Koiwai Dairy Products. We also declared our intention to switch to sustainable paper, such as FSC-certified paper and wastepaper, by 2030, and began related initiatives.

*Product photos are as of the end of June 2022.

Reducing the weight of paper containers

Lighter Cans

At Kirin Brewery, by reducing the diameter of the can ends and narrowing the top and bottom edges of the can body to reduce the weight of the can, as well as thinning out the walls of the can body, for our 350-ml aluminum cans, the current 204-diameter can end has achieved a weight reduction of approximately 29% compared to the old 209-diameter can end. This means an annual saving in aluminum resources* of approximately 19,000 tonnes. (*Kirin data from 2015 production volumes)
Further, working with can manufacturers, we developed an aluminum can with thinner can ends and bodies in 2016. The overall weight of the can has been reduced by approximately 5% (0.8 grams) from 14.6 grams to 13.8 grams. This represents a weight reduction of 33% (6.7 grams) from the 209-diameter can end.
In steel cans for beverages, the weight of the diamond-cut 190-gram steel can used for FIRE Hikitate Bito (low-sugar) coffee was reduced by 17% compared to the 2008 level in 2011.

Lighter returnable glass bottles

The lightest weight returnable bottle produced in Japan in all sizes (large, medium, and small). As well as being light in weight, returnable glass bottles need to be durable enough to maintain their returnable functionality and strong enough to ensure consumer safety and peace of mind.
To meet this challenge, the Institute for Packaging Innovation made excellent use of innovations such as a ceramic coating that forms a thin film on the bottle’s outside surface, an impact-resistant shape design, and a bottle mouth design that meets the conflicting requirements of being easy to open and able to be sealed tightly and that is also strong enough not to chip.

Reducing the weight of PET bottles

Lightest PET bottles for water produced in Japan

The Institute for Packaging Innovation has developed and put into practical use the lightest 2L PET bottle for water produced in Japan, at 28.3g.
We reduced the weight of the 2L PET bottle for Kirin Alkali Ion Water from 63g prior to June 2003 to 28.9g in 2015, and further reduced the weight in April 2019 by improving the bottle’s screw top, including making the screw threads narrower and the screw portion shorter, thereby making achieving the lightest such PET bottle produced in Japan and putting it into practical use. These efforts will result in annual reductions of PET resin use of approximately 107 tonnes and GHG emissions of approximately 375 tonnes.
For some 2L and 1.5L large PET bottle products, such as Kirin Gogo-no-Kocha and Kirin Nama-cha, we reduced the weight by approximately 16%, from 38.2g to 32.2g, by improving the molds of preforms used to make the PET bottles. We have been gradually introducing these bottles starting from products manufactured in December 2020. These efforts will result in annual reductions of PET resin use of approximately 439 tonnes and GHG emissions of approximately 1,515 tonnes.

* Kirin Alkali Ion Water was discontinued in September 2022. Using the same lightweight container, Kirin Natural Water Polished by Nature was sold in September 2022.

No label

PET bottles for wine

* An abbreviation for Diamond-Like Carbon (* Patent No. 4050648, etc.). A technology in which a thin film of carbon is formed inside a PET bottle, which suppresses the permeation of oxygen, water vapor, carbon dioxide, etc.

Use of roll labels for vending machine products

Since September 2020, Kirin Beverage has used “roll labels” on some PET bottle products for sale in vending machines.
There are two main types of label for PET bottled soft drinks: shrink labels and roll labels. We place shrink labels over bottles with a labeler in the filling plant, then apply heat to shrink the label. This means a certain thickness is required to prevent the label from bending. We do not use heat to shrink roll labels, instead attaching them by wrapping them around the PET bottle, which enables us to make the label thinner. Customers can easily remove the label by simply pulling the edge of the label, making it easier to sort trash, and thereby promoting recycling.
We are introducing roll labels for certain products exclusive to vending machines, such as Kirin Nama-cha and Kirin Gogo-no-Kocha Oishii Muto (sugar-free).

Shortening of labels and packaging materials

We have shortened the label on packaging for the 600ml Kirin Nama-cha and Kirin Nama-cha Hoji Sencha that we released in 2022. In addition to reducing the size of the label and making it thinner by switching to roll labels, this will result in annual reductions of resin use by approximately 180 tonnes and GHG emissions of approximately 400 tonnes.
We have made the paper packaging materials for the 525ml and 600ml products in the six-bottle packs of no label products shorter than those of the products we launched in 2021, thereby reducing paper consumption. We also use FSC-certified paper for packaging materials, and display a label of our certification.

Reuse

Re-use of glass bottles

In Japan, people have collected and re-used glass bottles over and over since the Meiji Era (1868-1912), long before the word “3R” was coined.
We wash returnable glass bottles that come back to the plant thoroughly inside and out to make them as clean as a new bottle. After stringently checking the bottles for scratches and cracks with an empty bottle inspection machine, we put them back into product service and fill them with beer. When handled carefully, returnable glass bottles last for an average of about eight years. This means they are used around 24 times.
When bottles have small scratches or fine cracks or are too old to be of service any longer, we crush them and turn them into a material called cullet, which we use as the raw material to make new bottles.

Recycling

Recycling of PET bottles

The Kirin Group promotes the recycling of PET bottles as a member of the Council for PET Bottle Recycling. Under the Council’s Fourth Voluntary Action Plan (FY2021-FY2025), we are working toward a target recycling rate of at least 85% (base year: FY2004).

Recycling of glass bottles

We turn old returnable glass beer bottles that can no longer be reused and one-way bottles which are used only once into cullet, for use primarily as the raw material for making new glass bottles. We are pursuing uses for cullet made from colored glass, which cannot easily be re-used for glass bottles. We are expanding potential ways to recycle this material for other applications, including in building materials such as tiles and blocks and road paving materials.

Recycling of cans

The Kirin Group is pursuing the adoption of aluminum cans that use a high rate of recycled metal. We have also joined the Japan Aluminum Can Recycling Association, and we are providing assistance for the collection of used aluminum cans as a way to promote their recycling.
Can manufacturers recycle aluminum cans discarded at breweries and use them as 100% aluminum cans for beer.

Promotion of recycling in Australia and New Zealand

Australia has Container Deposit Schemes in six of its eight states, and both remaining states have announced that they will implement this system in the future. Victoria and Tasmania are expected to commence schemes in 2023.
Lion plays an important role in Australia's Container Deposit Schemes. For example, in South Australia and the Northern Territory, Lion holds a majority of the shares of Marine Stores, a collection coordinator that aggregates collected materials for reuse and recycling. Lion also participates in Exchange for Change (EfC), a joint venture that coordinates the New South Wales and the Australian Capital Territory Container Deposit Schemes.
In Queensland and Western Australia, Lion participates in the administration and operation of Container Deposit Schemes as a member of the Container Exchange (QLD) Limited (CoEx) and WA Return Recycle Renew Limited (WARRRL), which were established and appointed as Producer Responsibility Organizations. Lion is a member of the nonprofit entities VicRecycle and TasRecycle, which intend to submit proposals to act as the coordinators of the Container Deposit Schemes in Victoria and Tasmania.
In New South Wales almost nine billion bottles and cans have been returned in less than four years of the scheme being in place, and there are currently 621 return points operating. The Queensland Container Deposit Scheme has been operating less than three years with nearly 5.4 billion containers returned and 341 return points in operation. The Western Australian Container Deposit Scheme commenced on October 1, 2020, and almost one billion containers have been returned. The South Australian scheme has been operating for over 40 years and recent reports stated the return rate of beverage containers sold is approximately 76.9%. In 2022, the South Australian government is considering improvements to modernize the scheme and further increase the rate of return. Lion is working with the state government to support the development and implementation of improvements. In the Australian Capital Territory, more than 270 million containers have been returned and recycled since the scheme began operating in December 2017. The Northern Territory scheme had a total return rate of 72% of containers sold.
New Zealand is also currently holding public consultations in relation to the implementation of a Container Deposit Scheme, which is expected to commence in 2025.

Graphs for Containers and Packaging