IFCO trays (also known as RPCs (the abbreviation for reusable packaging containers), or reusable containers, or reusable crates) are a type of reusable packaging for transporting fresh food produce. IFCO SYSTEMS is the name of the company that first developed a pooling service for reusable plastic trays for fresh produce in 1992, when the company was founded in Pullach, Germany. IFCO is the acronym for International Food Container Organization.
They are attractive for environmental reasons due to their ease of reuse, their capability of being stacked when full of produce in many different configurations and that they can be flattened when empty for compact return to producers/shippers/growers or for storage purposes.
The IFCO RPCs and trays are used for transporting perishable products and are available in different designs customized to the requirements of the produce. There are IFCO trays for fresh food, fruit and vegetables, bananas, baked goods, eggs, dairy, convenience foods, meat and fish. [1]
When the IFCO trays reach the end of their service life and can no longer be repaired, they are granulated and made into new IFCO RPCs. The raw material stream for the IFCO reusable crates is fully traceable. The company uses 100% of the available material from the broken or end-of-use crates. The IFCO trays generally have a life span of more than 10 years, before they are made into new crates. There is no packaging waste and there is a 100% material reutilization. [2]
IFCO trays are only available through the IFCO pooling service. Customers of the service share the reusable containers in a continuous closed loop. IFCO SYSTEMS refer to this pooling loop as the IFCO SmartCycle. [3]
IFCO supplies the reusable containers to farmers and producers of fresh produce and perishable items. Customers that use the SmartCycle are supplied with clean, sanitized IFCO RPCs at harvest or at the end of the production cycle. The produce is shipped or transported in the reusable plastic containers on pallets to the retailers, where the produce generally goes on display at the Point of Sale in the IFCO trays. This reduces the number of touchpoints with the produce and aims to reduce the potential for produce damage and waste, extending the shelf life of the fresh food produce in the process.
When empty and used, the reusable containers are recovered and returned to the IFCO wash centers, where they are checked, repaired (if necessary), washed, and then supplied to customers and used again.
The IFCO pooling service of RPCs and material reutilization is based on the circular economy model, which promotes the reuse, sharing, repair, refurbishment, remanufacturing and recycling within a closed-loop system in order to avoid waste and reduce the environmental impact of industrial designs.
Compared to disposable products and packaging, reusable containers help reduce the overall environmental impact of the fresh grocery supply chain.
As the IFCO trays can be folded compactly, they require less space in the reverse logistics as they are mainly the same size and are therefore compatible when folded. More IFCO RPCs can be stacked in trucks and in storage, saving food miles, energy consumption and storage costs.
The IFCO European line of Lift Lock reusable plastic containers (RPCs) are the first and only reusable food packaging containers to be awarded Cradle to Cradle Certified® (Version 3.1) at the Silver level by the independent non-profit Cradle to Cradle Products Innovation Institute, which is based on the Cradle to Cradle design philosophy of Michael Braungart and William McDonough. These IFCO trays were awarded Gold for Material Reutilization. [4]
The IFCO RPCs are washed and sanitized to food-grade quality after each use. The washing process is independently audited. [5]
Founded in 1992 in Germany, the company originally focused on Europe and expanded into the US market in 2003, when it launched the first Black RPC.
IFCO serves customers in over 50 countries, has offices in over 30 countries, 89 service centers and employs around 1,100 people. The company has a pool of over 314 million reusable plastic containers, which are used in over 1.7 billion shipments of fresh produce every year. Over 14,000 producers use the IFCO trays, and over 300 retailers.
IFCO is an independent company since its acquisition by Triton and Abu Dhabi Investment Authority (ADIA) in May 2019 from the Brambles company who had owned IFCO since 2011.
IFCO Systems has filed a total of 1,174 patents for the IFCO reusable plastic containers and pooling system. [6]
The company slogan is: “Make the fresh grocery supply chain sustainable”. [7]
Their adoption has generated controversy between developed countries which are consumers of produce and developing countries which are producers, primarily due to the cost of using the trays as opposed to using locally produced containers. In particular, many developing countries lack the capital-intensive infrastructure to develop and support the hi-technology plastic molding machinery necessary to produce the returnable trays. Analysis continues to compare the relative benefits of reusable trays, which require a full cycle (use, cleaning and return) versus one-time-use disposable containers which do not require return to the shipper, but instead are disposed of after one use. Disposable containers create a waste-disposal burden on recipients, while the returnable containers burden producers who must purchase containers and arrange for a return cycle. [8]
Post-consumer waste is a waste type produced by the end consumer of a material stream; that is, where the waste-producing use did not involve the production of another product.
A reusable bottle is a bottle that can be reused, as in the case as by the original bottler or by end-use consumers. Reusable bottles have grown in popularity by consumers for both environmental and health safety reasons. Reusable bottles are one example of reusable packaging.
Packaging is the science, art and technology of enclosing or protecting products for distribution, storage, sale, and use. Packaging also refers to the process of designing, evaluating, and producing packages. Packaging can be described as a coordinated system of preparing goods for transport, warehousing, logistics, sale, and end use. Packaging contains, protects, preserves, transports, informs, and sells. In many countries it is fully integrated into government, business, institutional, industrial, and for personal use.
Zero waste, or waste minimization, is a set of principles focused on waste prevention that encourages redesigning resource life cycles so that all products are repurposed and/or reused. The goal of the movement is to avoid sending trash to landfills, incinerators, oceans, or any other part of the environment. Currently 9% of global plastic is recycled. In a zero waste system, all materials are reused until the optimum level of consumption is reached.
A disposable is a product designed for a single use after which it is recycled or is disposed as solid waste. The term is also sometimes used for products that may last several months to distinguish from similar products that last indefinitely. The word "disposables" is not to be confused with the word "consumables", which is widely used in the mechanical world. For example, welders consider welding rods, tips, nozzles, gas, etc. to be "consumables", as they last only a certain amount of time before needing to be replaced. Consumables are needed for a process to take place, such as inks for printing and welding rods for welding, while disposable products are items that can be discarded after they become damaged or are no longer useful.
Intermediate bulk containers are industrial-grade containers engineered for the mass handling, transport, and storage of liquids, semi-solids, pastes, or solids. The two main categories of IBC tanks are flexible IBCs and rigid IBCs. Many IBCs are reused or repurposed.
Plastic milk containers are plastic containers for storing, shipping and dispensing milk. Plastic bottles, sometimes called jugs, have largely replaced glass bottles for home consumption. Glass milk bottles have traditionally been reusable while light-weight plastic bottles are designed for single trips and plastic recycling.
Waste minimisation is a set of processes and practices intended to reduce the amount of waste produced. By reducing or eliminating the generation of harmful and persistent wastes, waste minimisation supports efforts to promote a more sustainable society. Waste minimisation involves redesigning products and processes and/or changing societal patterns of consumption and production.
Cradle-to-cradle design is a biomimetic approach to the design of products and systems that models human industry on nature's processes, where materials are viewed as nutrients circulating in healthy, safe metabolisms. The term itself is a play on the popular corporate phrase "cradle to grave", implying that the C2C model is sustainable and considerate of life and future generations—from the birth, or "cradle", of one generation to the next generation, versus from birth to death, or "grave", within the same generation.
A bulk box, also known as a bulk bin, skid box, pallet box, bin box, gaylord, or octabin, is a pallet-size box used for storage and shipping of bulk or packaged goods. Bulk boxes can be designed to hold many different types of items such as plastic pellets, watermelons, electronic components, and even liquids; some bulk boxes are stackable.
A single-serve coffee container is a container filled with coffee grounds, used in coffee brewing to prepare only enough coffee for a single portion. Single-serve coffee containers come in various formats and materials, often either as hard and soft pods or pads made of filter paper, or hard aluminium and plastic capsules.
Recycling in Japan, an aspect of waste management in Japan, is based on the Japanese Container and Packaging Recycling Law. Plastic, paper, PET bottles, aluminium and glass are collected and recycled. Japan's country profile in Waste Atlas shows that in 2012 Recycling Rate was 20.8%.
Disposable food packaging comprises disposable products often found in fast-food restaurants, take-out restaurants and catering establishments. Typical products are foam food containers, plates, bowls, cups, utensils, doilies and tray papers. These products can be made from a number of materials including plastics, paper, bioresins, wood and bamboo.
Bottles are able to be recycled and this is generally a positive option. Bottles are collected via kerbside collection or returned using a bottle deposit system. Currently just over half of plastic bottles are recycled globally. About 1 million plastic bottles are bought around the world every minute and only about 50% are recycled.
Reusable packaging is manufactured of durable materials and is specifically designed for multiple trips and extended life. A reusable package or container is "designed for reuse without impairment of its protective function." The term returnable is sometimes used interchangeably but it can also include returning packages or components for other than reuse: recycling, disposal, incineration, etc. Typically, the materials used to make returnable packaging include steel, wood, polypropylene sheets or other plastic materials.
Plastic containers are containers made exclusively or partially of plastic. Plastic containers are ubiquitous either as single-use or reuseable/durable plastic cups, plastic bottles, plastic bags, foam food containers, Tupperware, plastic tubes, clamshells, cosmetic containers, up to intermediate bulk containers and various types of containers made of corrugated plastic. The entire packaging industry heavily depends on plastic containers or containers with some plastic content, besides paperboard and other materials. Food storage nowadays relies mainly on plastic food storage containers.
The history of bottle recycling in the United States has been characterized by four distinct stages. In the first stage, during the late 18th century and early 19th century, most bottles were reused or returned. When bottles were mass-produced, people started throwing them out, which led to the introduction of bottle deposits. However, during the second stage, after World War II, consumption patterns changed and nonreturnable containers became popular, which littered the environment. Some states implemented "bottle bills" that instituted deposits. The beverage-container industry first implemented private recycling programs and then pushed for municipal curbside recycling as an alternative to "bottle bills". More recently, PET bottles have largely replaced other materials. The United States used to be the front-runner when it came to recycling PET, but European countries have since outpaced the US.
Packaging waste, the part of the waste that consists of packaging and packaging material, is a major part of the total global waste, and the major part of the packaging waste consists of single-use plastic food packaging, a hallmark of throwaway culture. Notable examples for which the need for regulation was recognized early, are "containers of liquids for human consumption", i.e. plastic bottles and the like. In Europe, the Germans top the list of packaging waste producers with more than 220 kilos of packaging per capita.
Overpackaging is the use of excess packaging. The Institute of Packaging Professionals defines overpackaging as “a condition where the methods and materials used to package an item exceed the requirements for adequate containment, protection, transport, and sale”
Closed Loop Box Reuse, is the process by which boxes or other containers are reused many times. It is a form of reusable packaging.