INNOVATION - The Consortium

InnOvaTIve neW PrODuCT Background on the
product development
we’re
bananas
about Tru-Green!
From yummy bananas to useful envelopes
– it’s just a small leap.
In our search to find products that are truly different
and offer a really innovative approach to being
sustainable we came across a company looking for a
partner to develop a new line of envelopes.
Some of the important benefits of the Tru-Green
envelopes are:
1. We are using crop fibre padding made
from Jute. This is our starting option. Jute is
grown and a fibre cloth made in the North
Eastern region of India, particularly in the
state of Bengal. Growing and harvesting
Jute provides income to tens of thousands of
people in rural communities.
This material is renewable, natural, is
minimally processed and compostible.
Post use, the envelopes are a recyclable
or compostible waste - 98% of it. We are
working on designs to extend this to 100%.
Current padded envelopes use padding
made from plastic granules produced from
an ever depleting source - oil.
2.The designs lend themselves to using
other crop fibres/plant waste found in many
poorer regions of the world - providing
employment where most needed.
3.The current plastic padded
envelopes on the market go to land
fill and because the plastic is joined
to the paper, cannot be separated for
proper recycling.
4.There are padded envelopes
on the market that use recycled
paper fillings as padding but
from an energy life cycle point of
view, crop padding has the advantage
of minimal processing and hence less energy
is consumed in their production - a more
sustainable approach.
We have called the products Tru-Green
and are currently testing the market to
assess demand. To be one the first people
in the world to see this new product email
trugreen@theconsortium.co.uk.
COver STOrY
1. enveLOPe DeSIGn
The main criterion is to have a design
that is made from biodegradable and
compostible materials that are, where
possible, renewed by nature.
Minimal processing of these materials
to make the end product is the other
important aim to save on energy costs.
In the life cycle of the product, from raw
material to manufacturing, subsequent
despatch to customer and its post use
disposal, our aim is to minimise transport
costs to reduce carbon emissions.
We expect the fulfilment of above will lead
to a truly green product. Hence the brand
name “Tru-Green”.
2. DeSIGn FeaTureS
2.1 Outer paper has plant fibres and
recycled paper content.
2.2 Padding is not made from plastic
materials but minimally processed
crops to suit.
2.3 Inner paper is lightweight and made
from plant fibres and recycled paper.
2.4 User performance to match current
product on the market.
2.5 Printing ink used is not metal
based but natural materials that are
biodegradable.
2.6 To achieve user expectations in use of
the product we have had to use
1/1.5% by weight man made materials.
2.7 Colour used is also natural.
3. PaDDInG OPTIOnS
3.1 Banana stems and strips of these in
dried condition.
3.2 Jute mesh.
3.3 Pulped crop sheets that are embossed
to provide cushioning.
3.4 Cotton loom sandwiched and
alternatively stuck on in the inside.
3.5 Sandwiched or stuck on padding.
(Current first production run is
sandwiched padding made from jute).
4. GummInG OPTIOnS
4.1 Experiments with natural glues such
as starches and Tamarind glue did not
yield good results.
4.2 Work is continuing to find an organic
glue that is suitable.
5. manuFaCTurInG
5.1 This had to be evolved from
scratch. Development of blanks and
then blanking tools was undertaken.
Choosing the best presses for
flattening operations, gumming
fixtures and guns, paper strip
applicators for protecting the gum
was undertaken.
5.2 Production was broken down from 2
to 5 stage folding and assembly
operations.
This paper is from a sustainable forest