Proposal of a design tool combining performance criteria and circularity potential – A flexible film packaging application

The increasing production of plastic worldwide requires different alternatives to prevent this material from polluting the planet. Flexible polymeric packaging, for food applications holds a significant share, mainly due to the associated linear usage cycle. Therefore, developing new products with the potential for circularity is a goal of suppliers in this important supply chain. This paper proposes a packaging design methodology that considers performance criteria and the circularity potential of the final product in its conceptual phase. The developed tool combines the material selection methodology proposed by Ashby [8] and the circularity indicator MCI [7], proposed by Ellen MacArthur Foundation. The result is a decision flowchart, consisting of the stages: gathering packaging requirements (mechanical and protection), selecting materials that meet the requirements, constructing the matrix of possibilities, proposing packaging concepts, evaluating circularity potential, and ranking according to cost criteria. The tool was evaluated using a case study methodology, conducted in partnership with a representative company of the flexible packaging supply chain. Thus, technical and processing decision attributes were included in the flowchart, bringing industrial contributions to this design tool and proving the feasibility of its use in the development process of new packaging for food applications.