Huhtamaki LCA study: Paper cups have lower carbon footprint than reusable options when recycled

28 Jun 2019 --- Finnish paper-based packaging specialist Huhtamaki has participated in a study to analyze the life-cycle of various types of coffee cups, where it was found that paper cups generally have the lowest carbon footprint. Huhtamaki is the manufacturer of the plant polyethylene (PE) coated FutureSmart paper cup, which is made entirely from plant-based materials.

VTT Technical Research Centre of Finland carried out the 2018-2019 study, which was commissioned by Huhtamaki and the Finnish paperboard manufacturer Stora Enso. The research compared paper cups to ceramic cups in a café setting, as well as to reusable plastic cups in a takeaway scenario.

In the case of ceramic cups, washing up efficiency is a major determiner in the degree of environmental damage as it accounts for a reported 90 percent of climate impact. When the effects of washing are combined with raw materials and production, a ceramic cup would need to be used at least 350 times before it had a smaller carbon footprint than a paper cup. However, if at least 80 percent of the paper cup is recycled, they are always the more environmentally friendly option, the study found.

In the takeaway scenario, ecological costs were calculated for paper cups combined with a plastic lid to prevent accidents. In this case, the reusable plastic cup would need to be used at least 20 times to have a smaller climate impact than the paper cup. If the paper cup is later recycled, or if it is made with a plant PE coating, then it would take 32-36 uses of the reusable cup to break even.

In the case of Starbucks’ recent reusable coffee cup scheme in Gatwick Airport, the program would only be ecologically worthwhile if each reusable cup were cleaned in an energy-efficient way and reused frequently.

Greenhouse gas emissions per cup when recycled.

Policymakers can learn two big lessons from this study, Richard Ali, Sustainability Director for Huhtamaki Foodservice Europe-Asia-Oceania, tells PackagingInsights.

“Firstly, it is necessary to support paper cup recycling by including cups in the paper stream, as is the case in some European countries already. Secondly, we must recognize that items such as paper cups are the better option in many scenarios and can play a positive role if we are to combat climate change.”

The “huge recycling benefits” of the PE coated cup was of particular interest in the study, notes Ali. If a PE coated cup is entirely recycled, then the carbon footprint is reduced by 54 percent. Furthermore, the fiber in paper cups can be recycled up to seven times, although local legislation determines which products are able to use the recycled paper.

The FutureSmart paper cup
The Huhtamaki-developed paper cup is a notable example of a sustainable disposable receptacle. With the paperboard being sourced from PEFC-certified, sustainably managed forests, and the inside lining being made from plant-based PE, the cups are 100 percent renewable.

“As it is renewable, the PE coating has a lower carbon footprint than fossil-based polymers. The coating performs in the same way as traditional PE, delivering high standards of consumer safety and ensuring the cup is liquid-tight. The cup can be recycled with traditional paper cups,” explains Ali.

The FutureSmart cups are currently available in Finland, Norway, Sweden, Germany and Ukraine, and will shortly be available in other European countries including the UK. There are also plans to launch the cups in China.

“Looking forward, we are always looking to improve the design and specification of our paper cups. We are also extending our FutureSmart application to other packaging solutions in areas such as salad boxes, soup and food containers,” Ali concludes.

Stora Enso, the other Finnish packaging company who sponsored the study, also have a sustainable paper cup. The Cupforma Natura Solo cup does not use a traditional plastic coating later and can be recycled with full fiber recovery.

By Katherine Durrell