DNP Develops "Certified Nylon Film Packaging Materials"
Joint enterprise with BASF and KOHJIN Film and Chemicals
Dai Nippon Printing Co., Ltd. (DNP) has developed "Certified Nylon Film Packaging Materials" based on the use of renewable raw materials. This venture is a joint development with BASF of Germany and Tokyo-based KOHJIN Film & Chemicals Co., Ltd. (KJFC). BASF will be responsible for the manufacture of nylon resin, KJFC will produce the nylon film, and DNP will be responsible for the manufacture of nylon film based packaging materials.
The manufacturing process throughout the supply chain has received audit certification from a third-party certification organization, and the partners will establish a certified methodology and manufacturing system throughout the overall supply chain.
DNP is focused on the development of a variety of lower environmental impact, sustainability conscious packaging materials. In 2010 the Company developed a PE film partially based on plant-derived materials, and in 2012 led the world in the development of a similar PET film. DNP has since moved to enhance the plant-derived packaging materials series by commercializing such innovations as transparent vapor deposition film with augmented high barrier features against both oxygen and steam, an aluminum deposited film with superior barrier and light shading properties, and Linear Low-Density Polyethylene (L-LDPE) film.
These products make partial use of plant-derived materials, such as blackstrap molasses, a by-product of the production of sugar from sugar cane, and corn, and help reduce the use of petro-derived materials. Based on a Life Cycle Assessment (LCA) that quantitatively measures the environmental impacts, it was found that when compared to petro-derived plastic film, it is also possible to reduce greenhouse gas throughout the product lifecycle.
So far polyethylene terephthalate (PET) and polyethylene (PE) have been used as plastic packaging materials which contain renewable raw materials, but nylon - which is important for such packaging materials - has not. In order to overcome this challenge, DNP developed Certified Nylon Film Packaging Materials based on the use of renewable raw materials.
Certified Nylon Film Packaging Materials
The Certified Nylon Film Packaging Materials developed by DNP are based on the mass balance approach created by BASF, the world's leading comprehensive chemical manufacturer. The adopted technique mathematically allocates an effect from the substitution of renewable raw materials for petro-derived raw materials to the nylon resin. Verification is conducted in the following manner;
Assuming that nylon resin is manufactured with renewable raw materials (bio-naphtha and biogas), the necessary amount of renewable raw materials is calculated using a specific calculation formula to produce a set amount of nylon resin.
Input the necessary amount of renewable raw materials as calculated in 1 to a variety of products manufactured at the BASF plant, which usually use petro-derived raw materials. Thus substitution effect of the renewable raw materials for petro-derived materials is fixed.
Decide how much renewable raw materials used in 2 should be allocated to which nylon resin products.
Nylon film is manufactured at the KJFC factory using the nylon resin described in 3, and supplied to DNP, where it is deployed in the manufacture of Certified Nylon Film Packaging Materials.
In actual fact, renewable raw materials are not included in the manufacture of nylon resin, but by strictly managing renewable raw materials used in other products, and having third party certification organizations audit manufacturing and management systems, it is possible to invest the nylon film with a renewable raw materials-driven petroleum substitution effect.
The three partners aim to acquire third-party certification from TÜV SÜD of Germany in their respective manufacturing processes. BASF has already acquired accreditation, while DNP and KJFC are presently under audit.
In addition to being the responsibility of the company to procure renewable raw materials, it is also an important activity that leads to a high corporate assessment. The Certified Nylon Film Packaging Materials developed in this latest venture have been positioned as sustainable components, and as a result, help companies adopting this product to achieve assessments based on their environmentally friendly stances.
DNP film packaging materials based on renewable raw materials, such as refill pouches, have so far included 0-30% biomass content, but with this latest Certified Nylon Film Packaging Materials it has been made possible to regard nylon as a packaging material using 100% renewable raw materials. And by offering products with lower environmental burdens, it is also possible to contribute to the realization of a sustainable society.
DNP will market the new packaging materials to the manufacturers of daily necessities, aiming for sales of 3.0 billion yen in FY 2017, including sales of the biomass plastic packaging product series.
Going forward, DNP will contribute to the realization of a sustainable society by actively developing a variety of packaging materials with lower environmental loads.