Designed & manufactured non-woven laminated bag for a retailer named “Vatika Sarees” in the black color. Enhanced the brand name in metallic gold color as per the client’s pre-requisite.
The bag is manufactured in size “XL” using the roto-gravure + screen printing process.
Product Specifications
Item |
Description |
Bag Colour |
Black |
Bag Size |
XL |
Capacity (kg) |
10-12 kg |
Material |
Laminated Non Woven Fabric |
Printed |
Yes |
Printing Process |
Roto Gravure + Screen Printing |
Recyclable |
100% Recyclable |
Reusable |
Yes |
1. Materials Used
Sustainability:
- Recycled Content: The bag may be made from recycled materials, reducing the need for virgin resources. Using recycled materials often requires less energy and reduces waste in landfills.
- Biodegradable or Compostable Materials: If the bag is made from biodegradable or compostable materials, it can break down naturally without leaving harmful residues, reducing environmental impact.
Carbon Footprint:
- Renewable Resources: If the bag uses materials sourced from renewable resources (like plant-based plastics or paper), the carbon footprint is generally lower because these materials absorb CO2 during their growth phase.
- Efficient Manufacturing: Using materials that require less energy to produce or process reduces the carbon footprint. For instance, recycled aluminum uses 95% less energy compared to new aluminum production.
2. Production Processes
Sustainability:
- Energy Efficiency: Production processes that are energy-efficient contribute to sustainability by reducing greenhouse gas emissions. Factories using renewable energy sources (solar, wind, etc.) further lower the environmental impact.
- Waste Reduction: Sustainable production involves minimizing waste through efficient design and manufacturing processes, which can include recycling by-products and reducing offcuts.
Carbon Footprint:
- Low-Emission Manufacturing: Processes that generate fewer emissions (through cleaner energy use or more efficient technologies) contribute to a lower carbon footprint. Techniques such as water-based inks or solvent-free adhesives can be more environmentally friendly.
3. End-of-Life Considerations
Sustainability:
- Recyclability: A bag that can be easily recycled helps close the loop in a circular economy, reducing the need for new raw materials and the energy to produce them.
- Longevity: Durable products that can be reused multiple times reduce the demand for new products, decreasing overall material consumption and waste.
Carbon Footprint:
- Disposal Impact: Products designed to minimize environmental impact when disposed of (e.g., those that decompose quickly or can be upcycled) have a lower carbon footprint.
4. Scientific Explanation
Life Cycle Assessment (LCA):
- Comprehensive Analysis: Conducting an LCA provides a detailed understanding of the environmental impact of the bag from raw material extraction through production, use, and disposal. This includes calculating the total CO2 emissions at each stage.
Carbon Sequestration:
- Biobased Materials: If the bag uses plant-based materials, these plants capture CO2 from the atmosphere during their growth, which can offset some emissions associated with production.
Emission Reduction Technologies:
- Advanced Manufacturing: Implementing technologies that reduce emissions, such as improved insulation in production facilities or carbon capture and storage, can significantly lower the carbon footprint.
Steps for Calculation
- Raw Material Extraction and Processing:
- Identify the materials used (e.g., recycled paper, biodegradable plastic).
- Determine the carbon footprint per unit weight for each material.
- Manufacturing:
- Calculate the energy consumption during the manufacturing process.
- Identify the energy sources used (e.g., electricity, natural gas) and their carbon intensities.
- Transportation:
- Calculate the distance the product travels from the manufacturing site to the end user.
- Determine the transportation methods used (e.g., truck, ship) and their carbon intensities.
- Usage:
- Assess the product's lifespan and usage patterns.
- Consider any emissions associated with its use (usually minimal for a bag).
- End-of-Life:
- Determine the disposal method (e.g., recycling, composting, landfill).
- Calculate the emissions associated with each disposal method.
Example Calculation
Let's assume the following hypothetical data for the Eco Gold Shining Laminated Box Bag:
- Materials:
- Recycled paper: 50 grams
- Biodegradable plastic: 20 grams
- Carbon Footprint Data:
- Recycled paper: 0.5 kg CO2e per kg
- Biodegradable plastic: 1.0 kg CO2e per kg
- Manufacturing:
- Energy consumption: 0.1 kWh per bag
- Carbon intensity of electricity: 0.5 kg CO2e per kWh
- Transportation:
- Distance: 500 km
- Transportation mode: Truck
- Carbon intensity of truck: 0.1 kg CO2e per ton-km
- End-of-Life:
- Recycling rate: 80%
- Landfill rate: 20%
- Emissions from recycling: 0.1 kg CO2e per kg
- Emissions from landfill: 0.5 kg CO2e per kg
Calculation
- Raw Material Extraction:
- Recycled paper: 50 g×0.5 kg CO2e1000 g=0.025 kg CO2e50 \text{ g} \times \frac{0.5 \text{ kg CO2e}}{1000 \text{ g}} = 0.025 \text{ kg CO2e}50 g×1000 g0.5 kg CO2e=0.025 kg CO2e
- Biodegradable plastic: 20 g×1.0 kg CO2e1000 g=0.02 kg CO2e20 \text{ g} \times \frac{1.0 \text{ kg CO2e}}{1000 \text{ g}} = 0.02 \text{ kg CO2e}20 g×1000 g1.0 kg CO2e=0.02 kg CO2e
- Manufacturing:
- Energy consumption: 0.1 kWh×0.5 kg CO2e/kWh=0.05 kg CO2e0.1 \text{ kWh} \times 0.5 \text{ kg CO2e/kWh} = 0.05 \text{ kg CO2e}0.1 kWh×0.5 kg CO2e/kWh=0.05 kg CO2e
- Transportation:
- Weight of the bag: 70 grams (0.07 kg)
- Carbon footprint: 500 km×0.07 kg×0.1 kg CO2e/ton-km=0.0035 kg CO2e500 \text{ km} \times 0.07 \text{ kg} \times 0.1 \text{ kg CO2e/ton-km} = 0.0035 \text{ kg CO2e}500 km×0.07 kg×0.1 kg CO2e/ton-km=0.0035 kg CO2e
- End-of-Life:
- Recycling: 0.07 kg×0.8×0.1 kg CO2e/kg=0.0056 kg CO2e0.07 \text{ kg} \times 0.8 \times 0.1 \text{ kg CO2e/kg} = 0.0056 \text{ kg CO2e}0.07 kg×0.8×0.1 kg CO2e/kg=0.0056 kg CO2e
- Landfill: 0.07 kg×0.2×0.5 kg CO2e/kg=0.007 kg CO2e0.07 \text{ kg} \times 0.2 \times 0.5 \text{ kg CO2e/kg} = 0.007 \text{ kg CO2e}0.07 kg×0.2×0.5 kg CO2e/kg=0.007 kg CO2e
Total Carbon Footprint
Adding up all these contributions:
- Raw Material Extraction: 0.025 + 0.02 = 0.045 kg CO2e
- Manufacturing: 0.05 kg CO2e
- Transportation: 0.0035 kg CO2e
- End-of-Life: 0.0056 + 0.007 = 0.0126 kg CO2e
Total Carbon Footprint: 0.045+0.05+0.0035+0.0126=0.1111 kg CO2e0.045 + 0.05 + 0.0035 + 0.0126 = 0.1111 \text{ kg CO2e}0.045+0.05+0.0035+0.0126=0.1111 kg CO2e
References & Studies
To support these points with specific references and studies, consider the following:
- Recycled Material Benefits: Research shows that recycled materials, especially metals and plastics, have a significantly lower carbon footprint compared to their virgin counterparts (Hopewell, et al., 2009).
- Biodegradable Materials: Studies indicate that biodegradable and compostable materials reduce long-term environmental impact and contribute to lower greenhouse gas emissions (Song, et al., 2009).
- Life Cycle Assessments: Numerous LCAs demonstrate that products designed for recyclability or made from renewable resources have a smaller carbon footprint (Finkbeiner, et al., 2006).
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