Diseño de un envase para alimentos sostenible, inteligente e interconectado siguiendo los principios de la cuna a la cuna y utilizando el Análisis del Ciclo de Vida para la evaluación de impactos ambientales

125 ISSN 1688-6593 · INNOTEC 2020, No. 19 (125 - 141) REVISTA DEL LABORATORIO TECNOLÓGICO DEL URUGUAY CABOT, LUQUE, DE LAS HERAS, AGUAYO DESIGN OF A SUSTAINABLE, INTELLIGENT AND INTERCONNECTED FOOD CONTAINER... DOI: 10.26461/19.07 19 DOI: 10.12461/19.07 nota técnica Design of a sustainable, intelligentand interconnected foodcontainer following Cradletothe Cradle principles and using Life Cycle Analysis forthe evaluation ofenvironmentalimpacts Diseño de un envase para alimentos sostenible, inteligente e interconectado siguiendo los principios delacuna a la cuna y utilizando el Análisis del Ciclo deVida para la evaluación de impactosambientales Projeto de um contêiner de alimentos sustentável, inteligente e interconectado, seguindo os princípios do berço ao berço e usando aAnálise do Ciclo de Vida para avaliar os impactosambientais recibido: 7/9/2019 → aprobado: 26/11/2019 mariainescab[email protected] cabot, María i. (1); Luque, aMaLia (1); De Las Heras, ana (1); aguayo,Francisco(1) (1) DepartaMento De ingeniería DeL Diseño, escueLa poLitécnica superior, universiDaD De seviLLa, seviLLa,españa. resumen El objetivo principal de este trabajo es ayudar a combatir las pérdidas de alimentos en la cadena productiva, uno de los principales problemas de la industria alimentaria actual, incorporando conceptos de sostenibilidad. Según la FDA, cada año se arrojan alrededor de 1.300 millones de toneladas de alimentos. Los alimentos se desperdician principalmente a nivel de los hogares, por lo que se elige el diseño sostenible de un envase inteligente interconectado para uso doméstico. Para lograr esto, se exploran diferentes tecnologías, materiales, metodologías y marcos innovadores. En cuanto a los materiales, se estudiaron plásticos biodegradables, reciclados, reciclables y bioplásticos y se investigó la tecnología inteligente a utilizar, en este 126 ISSN 1688-6593 · INNOTEC 2020, No. 19 (125 - 141) REVISTA DEL LABORATORIO TECNOLÓGICO DEL URUGUAY CABOT, LUQUE, DE LAS HERAS, AGUAYO DESIGN OF A SUSTAINABLE, INTELLIGENT AND INTERCONNECTED FOOD CONTAINER... DOI: 10.26461/19.07 caso sensores. Respecto a las metodologías, se hace un estudio del Análisis del Ciclo de Vida (ACV) y la filosofía Cradle to Cradle (C2C). Los sistemas inteligentes de envasado son una opción para contribuir a minimizar el desperdicio de alimentos. El uso correcto de herramientas como el ACV, junto con los principios del C2C y la investigación sobre materiales y tecnologías pueden ayudar a los diseñadores a alcanzar una solución óptima que minimice los impactos ambientales. palabras clave: Economía circular, impacto ambiental, ecodiseño, envases inteligentes, industriaalimentaria. abstract The main objective of this work is to help combat food losses in the production chain, which is one of the main problems of the food industry today, incorporating also sustainability concepts. According to the FDA each year about 1,300 million tons of food are thrown. Food is wasted mainly at household levels, which is why the choice of the sustainable design of an intelligent interconnected packaging for domestic use is made. To achieve this, the exploration of different technologies, materials, methodologies and innovative frameworks is carried out. Regarding materials, the possibility of using biodegradable, recycled, recyclable and bioplastics was studied, along with the research of the intelligent technology to use, which ended up being sensors. As to methodologies, Life Cycle Analysis (LCA) and Cradle to Cradle philosophy (C2C) are studied. Intelligent packaging systems are an option to contribute to minimization of food waste. The correct use of tools such as the LCA, along with the principles of the C2C, and the research on materials and technologies to be used can help designers to reach an optimal solution, minimizing environmentalimpacts. Keywords: Circular economy, environmental impact, ecodesign, smart packaging, foodindustry. resumo O principal objetivo deste trabalho é ajudar a combater as perdas de alimentos na cadeia produtiva, um dos principais problemas da atual indústria de alimentos, incorporando também conceitos de sustentabilidade. De acordo com a FDA, cerca de 1,3 bilhões de toneladas de alimentos são lançadas a cada ano. Os alimentos são desperdiçados principalmente no nível doméstico, por isso foi escolhido o design sustentável de um contêiner inteligente interconectado para uso doméstico. Para isso, diferentes tecnologias, materiais, metodologias e estruturas inovadoras sãoexploradas. Com relação aos materiais, foram estudados plásticos biodegradáveis, reciclados, recicláveis e bioplásticos e investigada a tecnologia inteligente a ser utilizada, neste caso sensores. Com relação às metodologias, foi realizado um estudo da filosofia do Ciclo de Vida (ACV) e da filosofia Cradle to Cradle(C2C). 127 ISSN 1688-6593 · INNOTEC 2020, No. 19 (125 - 141) REVISTA DEL LABORATORIO TECNOLÓGICO DEL URUGUAY CABOT, LUQUE, DE LAS HERAS, AGUAYO DESIGN OF A SUSTAINABLE, INTELLIGENT AND INTERCONNECTED FOOD CONTAINER... DOI: 10.26461/19.07 Sistemas de embalagem inteligentes são uma opção para ajudar a minimizar o desperdício de alimentos. O uso correto de ferramentas como a ACV, juntamente com os princípios do C2C e a pesquisa de materiais e tecnologias pode ajudar os projetistas a alcançar uma solução ideal que minimiza os impactos ambientais. palavras-chave: Economia circular, impacto ambiental, design ecológico, embalagens inteligentes, indústria dealimentos. introduction The problem of food waste According to Food and Agriculture Organization, “food waste” can be defined as food that is appropriate for human consumption but is discarded before it is spoiled, as a result of negligence or conscious decision to throw away food (Heising, etal.,2017). Expert advisors to the United Nations estimate that, around the world today, about 30% of the food grown is lost due to deterioration (Russell, 2014). Others are encouraged to say that even 40% of all food intended for human consumption in developed countries ends up being a waste (Heising, etal.,2017). In tons, according to the 2011 FDA report, about 1.3 billion tons of food is thrown away every year (Dobrucka and Cierpiszewski,2014). Food waste quantification by category of food in households has been studied by Williams and Wikström (2010), who showed that fruits and vegetables, prepared foods and dairy products are the ones that contribute the most to waste when expressed based on weight (Heising, etal.,2017). Prevention of avoidable food waste generation along the supply chain represents the most advantageous option within the food waste hierarchy (Heising, etal.,2017) and optimal packaging for each food can help reduce all these numbers. Promptly in middle and high income countries, food is wasted mainly at retail and consumption levels (Russell, 2014), and this is the reason why this research work is aimed at smart packaging at the domesticlevel. The entire value chain has a responsibility to explain that sustainability is not synonymous of recycling, recyclability, recycled content, biodegradability and other buzzwords, but that main efficiency of supply chain resources should be the top priority (Russell,2014). Sustainability and packaging Improving sustainability requires knowledge of complete value chains; focus on one section is insufficient since solving a problem in one place can result in the creation of a different problem in another (Russell,2014). Specially in terms of packaging, since, due to their inherent dependencies, life cycles of the product/packaging combinations are more complex than the individual life cycles for the products (Abramovici,2013), as can be seen inFigure1. 128 ISSN 1688-6593 · INNOTEC 2020, No. 19 (125 - 141) REVISTA DEL LABORATORIO TECNOLÓGICO DEL URUGUAY CABOT, LUQUE, DE LAS HERAS, AGUAYO DESIGN OF A SUSTAINABLE, INTELLIGENT AND INTERCONNECTED FOOD CONTAINER... DOI: 10.26461/19.07 Packaging manufacturing (parts) Product manufacturing (parts) Raw materials Raw materials Distribution Raw materials processing Product-container combination Use by the consumer Raw materials processing Reuse, recycling, incineration Reuse, recycling, incineration DumpDump Content deletionContainer disposal Figure 1. Life cycles of the product, the container and their superposition. There are many attributes that can contribute to a more sustainable food package, such as it being produced from recycled material, or that it minimizes the use of water, generates zero waste in landfills, has the potential to be reused, is made using renewable energy, does not generate air pollution, does not generate greenhouse gas emissions, protects human health, etcetera. In fact, all these attributes can be valid and valuable, however, no solution meets all sustainability criteria at the same time (Russell, 2014). The main criterion with which it must comply is to offer, first and foremost, its content to the consumer in good condition (Russell, 2014) because by containing, protecting and preserving its contents, packaging contributes to important social aspects of sustainability, such as health and the need for food (Abramovici, 2013). For example, when the shelf life of a cucumber can be extended from three days to more than two weeks simply by wrapping it in 1,5 g of packaging, the food supply chain becomes much more sustainable and means that the small amount of polyethylene used is a good candidate to be called ‘sustainable packaging’ (Russell, 2014). A more comprehensive and integrated approach, which encompasses economic, social and environmental considerations, along with more efficient packaging designs that save materials and are recyclable, is the key to sustainable packaging (Lee and Xu, 2005). In this context, Life Cycle Assessment (LCA) can be applied as a design support tool to highlight criticisms regarding environmental aspects and improvement solutions in the life cycle of packages, thus promoting the use of greener products (Siracusa, etal.,2014). For decades, the dominant environmental problems in the packaging area have been optimization of materials and possibilities of recycling, and not the reduction of food losses. However, for all the above, it is concluded that the principle of avoiding food losses should be included in the packaging design if the overall environmental impact of the food packaging system aims to be reduced. 129 ISSN 1688-6593 · INNOTEC 2020, No. 19 (125 - 141) REVISTA DEL LABORATORIO TECNOLÓGICO DEL URUGUAY CABOT, LUQUE, DE LAS HERAS, AGUAYO DESIGN OF A SUSTAINABLE, INTELLIGENT AND INTERCONNECTED FOOD CONTAINER... DOI: 10.26461/19.07 The ideal is to find new packaging solutions that not only reduce the impact of the packaging itself, but also reduce the losses of the food it contains. However, it should be borne in mind that, in some cases, it may be necessary to increase the environmental impact of the new packaging to reduce food losses. It is important to analyze whether there is a risk that food losses increase when the design of the package changes, for example, when it is sought to reduce the amount of packaging material. The total environmental impact will surely increase if this decision implies an increase in food losses, even if the impact of the packaging decreases. Environmental impact is generally higher for products of animal origin such as meat and milk than for vegetable products. Regarding the environmental impact of the food/environmental impact of the container, the following comparison can be made: a refined food product with an animal origin such as cheese has a high environmental impact per kilogram. The polyethylene cheese package has a relatively low environmental impact per kilogram of cheese. This means that large increases in cheese packaging could be justified for a new package that reduces the losses of this product. The F/T ratio (environmental impact of the food/environmental impact of the container) is much lower for ketchup, a refined article with vegetable origin, for which the packaging solution has a high environmental impact. The low F/T ratio indicates that it is probably as important to find packaging systems with less environmental impact than to develop packages that reduce ketchup losses (Williams and Wikström, 2010). Moreover, consumer behavior has probably the greatest potential to reduce food losses, and packaging can influence their behavior through the provision of information and/or technical solutions. Printed information on how to store the contents, how to improve interpretation of expiration dates, etcetera, may affect this parameter, so it is important to carry out research on the extent to which losses can be influenced by the communication power of the packaging. Smart packaging in the food industry New packaging solutions allows to improve the economic aspect of food waste and the interest in active and intelligent packaging is increasing. This is reflected in the number of patent applications and patents granted in recent years (Barska and Wyrwa,2017). One of the major causes of waste is fixed expiration dates, since consumer’s willingness to pay for a food product generally decreases if there are fewer days left before the expiration date. This means that as soon as a new batch of product with a longer shelf life enters the supermarket, consumers will probably buy these new products instead of the older ones, and after the expiration date the supermarket will have to discard those products (Heising, etal.,2017). Therefore, there are studies that propose the establishment of a dynamic expiration date, with a potentially dynamic price, that is, lowering the price as the expiration date approaches. In this system, the price of the food is automatically 130 ISSN 1688-6593 · INNOTEC 2020, No. 19 (125 - 141) REVISTA DEL LABORATORIO TECNOLÓGICO DEL URUGUAY CABOT, LUQUE, DE LAS HERAS, AGUAYO DESIGN OF A SUSTAINABLE, INTELLIGENT AND INTERCONNECTED FOOD CONTAINER... DOI: 10.26461/19.07 adapted from an electronic signal of a quality sensor, depending on the expected remaining useful life, influencing the purchase decision of consumers and, as an expected result, should have a lower number of expired products before sale and consumption, thus reducing avoidable food waste (Heising, etal.,2017). This is possible with smart packaging. Deterioration of the intrinsic quality attributes of food products must be studied in depth to determine which smart packaging concept is the most useful for implementing and monitoring or ensuring good product quality. Smart containers are systems used to detect, perceive and record any changes within the package (Mohebi and Marquez, 2015) during their life cycle and communicate this information related to the quality or safety of the packaged product (Heising, etal.,2017) in order to improve safety and quality as well as to warn about possible problems during transport and storage of food (Mohebi and Marquez, 2015). These use properties or components of the food or some material of the container as indicators of the history and quality of the product. Unlike active packaging, smart ones do not intend to release components into the food (Biji, etal.,2015). These containers are based on two systems. The first one is based on the measurement of the conditions outside the packaging, while the second one measures directly the quality of the food products inside the packaging and can come into direct contact with the food, therefore, additional safety and quality controls are required (Barska and Wyrwa,2017). The appearance of intelligent packaging systems has contributed to a significant change in the existing perception of packaging, since they transform traditional functions of communication into intelligent communications (Barska and Wyrwa, 2017), thus forming an extension of the function of communication of traditional packaging (Biji, etal.,2015). If this technology were combined with low impact packaging systems, there would be an increase in the environmental sustainability of the food packaging and preservation solution. In addition to this, if the food contained were produced using processes and products with low environmental impact, all packaged food would be more sustainable (Siracusa, etal.,2014). Objective The objective of this research work is the design of an intelligent interconnected container of rigid plastic, whose main specification is the storage of climacteric fruits in the refrigerator of a standard household and monitor the ethylene content. At the same time, it aims to inform consumers, through Bluetooth connection, that the fruit it contains is at its optimal date of consumption, thus avoiding foodwaste. This package is designed in a way that can be transported from home to the supermarket every time a purchase is made, which means savings in disposable plastic containers used in the packaging of this type of products. It is made of plastic in order to adapt, since it is in this material that most of the innovations for packaging are made. Its resistance property is prioritized, as it is key to achieving the desired usefullife. 131 ISSN 1688-6593 · INNOTEC 2020, No. 19 (125 - 141) REVISTA DEL LABORATORIO TECNOLÓGICO DEL URUGUAY CABOT, LUQUE, DE LAS HERAS, AGUAYO DESIGN OF A SUSTAINABLE, INTELLIGENT AND INTERCONNECTED FOOD CONTAINER... DOI: 10.26461/19.07 Sensors will be the chosen technology for the intelligent part of the package, since they are the most successful technology for the detection of volatile compounds such as ethylene. Compared to indicators, sensors are faster, more precise and reliable, and they also provide necessary information on the quality of food in real time. The chosen sensors are called MOSFET and it is of special relevance that the reaction with ethylene has reversibility, since the container willbereused. For its design, Cradle to Cradle principles are considered and after the container is designed, Life Cycle Analysis is performed in order to look for the process optimizationpoints. materials and methods Materials Evaluation of materials to use Bioplastics and biodegradableplastics To declare that a product is more sustainable it is not enough to know what raw material is used for its manufacture, it is also necessary to understand where and how that raw material is produced. Then there are confusing terms like ‘bioplastic’. This may mean what is best described as ‘bio-based’ plastic produced from renewable raw material sources or it may mean ‘biodegradable’ plastic. The former refers only to the origin of the raw materials from which plastics are manufactured, while the latter is about its end of life. The key point is that biologically-based plastics may not be biodegradable (for example, biologically based polyethylene) and a biodegradable plastic may not be biologically based (for example, fossil-based aliphatic-aromatic copolyesters that are used to make biodegradable films) The main challenge for raw materials of biological origin is that conversions are required to move from biological raw materials to useful molecules. Usually, that requires energy (about twice the energy for polyethylene obtained from sugarcane than for synthetic polyethylene), and if that energy is supplied by fossil fuels, which it usually is, then emissions from CO2 can be increased instead of decreased (Russell,2014). In addition, the environmental advantages of the new biological materials are sometimes less than the expected due to comparatively high energy consumption in one or more of the production stages. This is also due in part to the fact that these materials have a less favorable barrier and mechanical properties, resulting in greater material inputs (Hermann, etal.,2010). As for biodegradable plastics, although the biodegradability that supports compostability according to national standards such as UNE-EN 13432 (Asociación Española de Normalización y Certificación, 2001) is a useful property for specific applications in locations where industrial composting facilities exist, it is not a universal solution for the sustainable management of packaging waste or a viable solution to problems such as garbage, which is a problem of social behavior and should be addressed as such (Russell,2014). 132 ISSN 1688-6593 · INNOTEC 2020, No. 19 (125 - 141) REVISTA DEL LABORATORIO TECNOLÓGICO DEL URUGUAY CABOT, LUQUE, DE LAS HERAS, AGUAYO DESIGN OF A SUSTAINABLE, INTELLIGENT AND INTERCONNECTED FOOD CONTAINER... DOI: 10.26461/19.07 Recycled raw material and recyclable containers If recycled polymers were used, impacts due to the production phase would decrease proportionally. On the other hand, if packages are produced to be recyclable after disposal, impacts due to the end of life would be reduced (Siracusa, etal.,2014). Collecting and recycling used containers helps preserve the financial and energy inputs that came in to create the material and reduce environmental burdens by not requiring the creation of new packaging material, but only to the point where collection, classification, cleaning and reprocessing is cheaper, requires less energy and causes less unwanted emissions than virgin packaging production. In addition, the more dispersed or contaminated the packaging material is, the less sustainable its mechanical recycling will be (Russell,2014). When considering a Life Cycle Analysis, it is clear that single-layer packaging is more desirable from an environmental point of view, since, in principle, it uses less material and energy in its manufacture. But we must also consider that multilayer packaging is having a great impact on the market because it provides the product a longer shelf life and therefore needs less energy for its conservation and distribution (Lee and Xu, 2005). This is what will be prioritized in thisstudy. In addition, it is essential to obtain containers and films with good gas barrier properties for the packaging of perishable products such as food and beverages, and for this the need to manufacture this type of packaging is oftenimperative. A bilaminar plastic container was then chosen, with PET in the outer layer and HDPE in the inner layer. As an adhesive that joins both layers, the commercially known copolymer Surlyn is used since a correct behavior was observed in the research work carried out by Guerrero and Arroyo(2003). The chosen criteria were costs, availability and properties (high hardness, washability, aptitude for food contact, low oxygen permeability and low water vaporpermeability). Methods Cradle to Cradle (C2C) Cradle to Cradle (C2C) is an innovation framework used since the 1990s in order to design products and services that are beneficial in economic, health and environmental terms to achieve a sustainable world (Ankrah, etal.,2015). Conceived by architect William McDonough and chemist Michael Braungart, it proposes to replace eco-efficiency with eco-efficacy and has as its mother premise that a closed cycle system does not need to be eco-efficient (reduce the use of resources and waste) because the more waste is generated, more nutrients are available to produce new products (Kausch and Klosterhaus,2016). A comparison between eco-efficiency with eco-efficacy can be seen in Figure 2. 133 ISSN 1688-6593 · INNOTEC 2020, No. 19 (125 - 141) REVISTA DEL LABORATORIO TECNOLÓGICO DEL URUGUAY CABOT, LUQUE, DE LAS HERAS, AGUAYO DESIGN OF A SUSTAINABLE, INTELLIGENT AND INTERCONNECTED FOOD CONTAINER... DOI: 10.26461/19.07 1st distribution Production End of lifeUseResource exploitation Transformation Logistics Distribution Client Cradle to Cradle (Eco-efficacy) Cradle to grave (Eco-efficiency) 2nd distribution Reverse logistics Figure 2. Comparison between eco-efficiency (Cradle to grave) and eco-efficacy (Cradle to Cradle). It is proposed that eco-efficiency is a reactionary approach that does not address the need for a fundamental redesign of industrial material flows and is primarily a strategy for damage management and the reduction of guilt. Cradle to Cradle is based on the premise that making small changes in a system that is fundamentally incorrect and can never achieve anything ‘good’, it will only reduce the ‘bad things’ just a little (Hesselbach and Herrmann,2011). In C2C the assumption that industry inevitably destroys the natural environment is rejected, recognizing the potential within the economy of abundance, the power of ingenuity, creativity and prudence, imagining systems that, together with their technical functionality, purify water, the atmosphere and the soil, helping nature create environmental value (Peralta-Álvarez, etal.,2011). The two cycles of C2C C2C states that, for the flows generated by the industry, two possible metabolic pathways associated with a technosphere and a naturesphere are established and must be considered in the design of industrial products and systems (Peralta- Álvarez, etal.,2011). Biological nutrients are metabolized and regenerated by the naturesphere (Peralta-Álvarez, etal.,2011) and are defined as: “A material used by living organisms or cells to carry out vital processes such as growth, cell division, carbohydrate synthesis and other complex functions. They are materials that can be biodegraded safely” (Hesselbach and Herrmann,2011). Technical nutrients, which make up the technosphere, are defined as: “A material that remains in a closed cycle manufacturing, reuse and recovery system called technical metabolism, maintaining its value through infinite product life cycles.” (Hesselbach and Herrmann,2011) Metabolisms in C2C Three metabolisms are recognized for the products. 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