Design Life-Cycle

 Haleigh McCormack

DES 040A

Cogdell

5 June 2024

Raw Materials in the Production of Bubble Wrap and Air Bubble Film Machine

Introduction

The production of bubble wrap requires the use of many more raw materials than just plastic.  It takes many steps to actually reach the point of a plastic product.  The main material that is used to create bubble wrap is called polyethylene.  This is the most widely used commodity plastic.  It is used in many ways, but in this case, it is constructed with tiny air pockets that provide support and cushion for whatever it is used to wrap.  The surge in online shopping has led to a mass production of bubble wrap, as well as an increase of building of the machine that makes this product, called the bubble wrap air machine (Bazigian 2024).  240,000 miles of bubble wrap are produced every year.  It is such a highly used product due to its cost effectiveness as it uses cheap materials.  This paper will focus on the life cycle of the raw materials that go into making plastic bubble wrap and air bubble film machines, and how this affects our environment.  

Raw Material Acquisition 

In order to create the machine that makes bubble wrap, the most essential material is steel (Chang 2023).  This material is derived from iron ore, which originates from oxygen and the raw material iron.  Once iron is mined from the earth, it is mixed with carbon at 2,900 degrees fahrenheit, finally producing steel.

The process of creating polyethylene starts with obtaining crude oil.  In order to obtain this oil, workers are required to drill into the earth through the process of hydraulic fracturing, also known as fracking.  This method creates fractures in rock formations by injecting fluid into cracks to break them open even further.  After crude oil is drilled from the earth through fracking, it combines with natural gas concentrate to produce ethylene as a byproduct.  Oil is used again during the process of acquiring raw materials, as it is used to transport polyethylene to processing factories by trucks or trains that use gas and oil as fuel.  Once it is transferred to the next location, the manufacturing process can begin.

Product Manufacturing 

After crude oil combines with natural gas concentrate, ethylene is created, which allows us to begin manufacturing the product.  From here, it can be polymerized into polyethylene with the help of a suitable catalyst, such as metallocene or Ziegler-Natta-type catalysts (Petani 2024).  Coordination Polymerization is the most commonly used process to create polyethylene.  The chemical process of creating this form of plastic needs a free radical to be introduced to the ethylene molecule.  It causes a bond to break between two carbon items.  An open bond is created, leaving room to connect with another molecule.  Eventually, a polyethylene polymer chain emerges as this process continues.  Long filaments are extruded from the polymer after it becomes polymerized.  Finally, these filaments run through a pelletizer that cuts the filaments into small pellets that can be shipped and processed.  Oil is used to transport these small pellets, as they are often sent out on planes (Sharpe 2016).  

Once polyethylene reaches manufacturing factories, the true process of putting together the actual product, bubble wrap.  The polyethylene is combined with more small pellets, made of nylon and flex, which each provide the necessary properties to construct this product.  The nylon gives it strength, and flex provides adhesive that is necessary to create the air filled bubble.  An extruder vacuums up the pellets and heats them at temperatures of 450 to 512 degrees.  This causes the pellets to become liquid, and they are then squeezed out and formed into two sheets stacked on top of one another.  Holes are punctured, and then the film is laminated to trap air bubbles inside (Fitz 2020).  Distribution of the product can begin after the final step of inserting air into the plastic is complete.

Distribution and Transportation

At the start of plastic production, natural gasses such as propane and ethane are transported to petrochemical plants to become polymerized.  This transportation takes place by pipeline, truck, or rail (McGuire 2020).  Pipelines are powered by electric motors, diesel engines, or gas turbines.  Diesel also works to fuel trucks and trains.  This makes crude oil the main raw material used to power the transportation and distribution of the raw materials that contribute to making plastic.

After the materials become polymerized, they are transferred to their final factory with the goal of becoming bubble wrap.  Once again, they are transported by trains, which require diesel fuel, created by crude oil and biomass.  Before it is officially ready to be shipped for distribution, the product is wrapped in another plastic sheet and packaged in a paper box.  Then, it is typically transferred to an ocean carrier and shipped overseas, fueled by crude oil once again.  After the product is distributed, it is ready to be put to use.

Use/Re-use and Maintenance

Bubble wrap is used when packing fragile items in order to keep them safe and secure to prevent breakage.  It is particularly used to support shipping other products, which are put on planes fueled by jet fuel or trucks that use diesel.  This makes crude oil the main raw material used once again.  After the product has been used, it can absolutely be reused over and over again.  The individual in possession of the process can use it to wrap any other fragile items they please, and the bubble wrap will successfully serve as a cushion as long as it is cared for well.  The nylon in bubble wrap makes this material stretchy, and easy to tear.  If it tears and the bubbles lose air, there is no longer any support provided by this product.  As long as the user takes careful care of this product, the life cycle of bubble wrap can be extended tremendously.  Once the use and reuse is complete, the recycling process can begin.

Recycling 

There are many different methods to dispose of bubble wrap after use is completed, and sometimes it is not done in the most effective way.   It contributes to a large portion of our world’s waste, despite its recyclability.  Some forms of bubble wrap are composed of a low density polyethylene that clogs the machines that process recycling.  This poses a threat to the equipment as well as the individuals recycling.  For this reason, it should not be placed with everyday recycling.  Instead, it should be disposed of separately.  Non-recyclable bubble wrap is dumped into landfills, where it takes 10-1,000 years to decompose completely.  The materials create a barrier that prevents fungi from getting through and breaking down materials (Leahy 2023).  The process of distribution alone creates a substantial amount of waste as it wraps the plastic bubble wrap in more plastic and cardboard before departure.  Cardboard can easily be disposed of in your curbside recycling bin, but the plastic wrap goes right into the landfill alongside bubble wrap (De L’oseraye).  Bubble wrap that is composed of a higher density polyethylene is eligible for recyclability.  It can be grouped with other soft plastics and brought to recycling units that are designated for plastic film, typically found at your local grocery store.  Bubble wrap that does not get recycled gets added to landfills as waste.

Waste Management

As of 2018, the total amount of plastic filling landfills is 27 million tons.  This includes polyethylene terephthalate and high density polyethylene (EPA 2024).  Even when the process of recycling is possible, the quality of the material degrades.  The decrease of quality only makes it possible to be recycled once (Ritche 2024).  Due to this reason, bubble wrap ends up in landfills even after going through an additional life cycle.  It just delays the inevitable.  However, the increased production of bubble wrap due to online shopping has caused companies to rethink their environmental sustainability efforts.  There are current plans to improve recycling abilities that will be able to process low density polyethylene.  This plan would provide positive improvements to the current method of recycling because it involves a new chemical formula that creates a plastic that is easier to decompose (Mitchem 2023).  

Conclusion 

In conclusion, bubble wrap and the bubble wrap air machine require a plethora of raw materials to carry out their life cycle.  Some of these materials create difficulties, especially towards the end of the life cycle in regards to recycling and waste management.  The majority of companies use low density polyethylene which causes bubble wrap to end its life taking up space in a landfill.  Even though some forms of bubble wrap are capable of being recycled, many people do not know how to properly execute this process, creating issues for our environment.  However, even the start of this life cycle requires the use of problematic materials.  Fossil fuels are the base of the entire product, and the use of these raw materials have detrimental effects towards climate change.  Luckily though, there are currently efforts in the work to improve environmental sustainability efforts by producing more high density polyethylene to create bubble wrap.  The use of bubble wrap will not be slowing down as the rate of consumption is at an all time high.  Moving forward with these sustainability efforts will allow for a new life cycle process to produce this product without creating as much waste.

Bibliography 

Bazigian, Craig. “How Does Bubble Wrap Contribute to the Overall Revenue of the Packaging Company in 2023?” BayWater Packaging, 2 Jan. 2024, www.baywaterpackaging.com/how-does-bubble-wrap-contribute-to-the-overall-revenue-of-the-packaging-company-in-2023/.

Chang, Chi. “All You Need to Know About Air Bubble Film Making Machines.” CHI CHANG, CHI CHANG MACHINERY ENTERPRISE CO., LTD., 21 Nov. 2023, www.extrusion.com.tw/en/news_i_all_about_air_bubble_film_machines.html#:~:text=Air%20bubble%20film%20extrusion%20machine,the%20familiar%20bubble%20wrap%20texture.

De L’oseraye, Zane. “Polyethylene HDPE Recycling: Cap Eco Recycling.” Capeco Recycling, 27 Sept. 2023, capeco-recycling.com/en/how-to-recycle-polyethylene-pe/.

Fits, Elza. “How Is Bubble Wrap Manufactured?” Safe Packaging, 16 Oct. 2020, safepackaginguk.com/how-is-bubble-wrap-manufactured/. 

Leahy, Meredith. “Is Bubble Wrap Recyclable?” Rubicon, 6 Feb. 2023, www.rubicon.com/blog/is-bubble-wrap-recyclable/.

McGuire, Ray. “Transportation: Delivering the Plastic Products You Can’t Live Without.” UP, 2 Apr. 2020, www.up.com/customers/track-record/tr020420-transportation-and-plastics.htm.

Mitchem, Savannah. “Scientists Enhance Recyclability of Waste Plastic.” Scientists Enhance Recyclability of Waste Plastic, Argonne National Biography , 14 Mar. 2023, www.anl.gov/article/scientists-enhance-recyclability-of-waste-plastic.

Petani, Sungai. “The Journey of Plastic Resin: A Deep Dive Into the Manufacturing Process.” Thong Guan Industries, 14 Mar. 2024, www.thongguan.com/plastic-resin-made-exploring-process/.

“Plastics: Material-Specific Data.” EPA, Environmental Protection Agency, 2 Apr. 2024, www.epa.gov/facts-and-figures-about-materials-waste-and-recycling/plastics-material-specific-data.

Ritchie, Hannah. “FAQs on Plastics.” Our World in Data, 2 Feb. 2024, ourworldindata.org/faq-on-plastics#:~:text=Plastics%20typically%20degrade%20in%20quality,use%20cycle%20as%20another%20product.

Sharpe, Pete. “Making Plastics: From Monomer to Polymer.” AIChE, 26 July 2016, www.aiche.org/resources/publications/cep/2015/september/making-plastics-monomer-polymer#:~:text=Polyethylene%20(PE)%20is%20a%20made,molecular%20weights%20in%20the%20millions.

Rableen Kaleka

Aisha Rahman, Haleigh McCormack, Rableen Kaleka 

Professor Christina Cogdell 

DES 040A

5 June 2024 

Life Cycle Assessment of Bubble Wrap & Air Bubble Machine: Embodied Energy

Introduction

Despite its ubiquity in our daily lives, bubble wrap, a simple and endlessly versatile material, often escapes the conscious consideration of the impacts of its mass production. U.S. engineer, Alfred Fielding, and Swiss chemist, Marc Chavannes, first developed the item in 1957, but not as a packaging product. Bubble wrap was initially developed to be a new kind of wallpaper, but its lack of success as a wallpaper turned into the widely used packaging product that serves multiple applications. The first-ever bubble wrap was made by putting together two shower curtains and sealing the seams together. Fielding and Chavannes trapped air bubbles inside the curtains, creating a slim and transparent cushion. With this prototype, the two inventors aimed to create a machine that automated the procedure. Using the machine, they hoped to create a plastic wallpaper with a paper backing. Unfortunately, the machine only created air bubbles inside the plastic sheets. After three years, with the help of Frederick Bowers, the inventors marketed the bubble paper as a packaging tool ("The Story Behind Bubble Wrap"). Bubble wrap has an abundance of applications across various domains, serving as a protective packaging material for fragile items during shipping, an insulating layer for greenhouse gardening, a cushioning agent in orthopedic casts, a tool for stress relief through popping bubbles, and even as an artistic medium for creating textured paintings and sculptures. Its versatility and affordability make it a staple and in high demand in both industrial and domestic settings. 

As mass production of products has significantly increased alongside consumerism, it is critical to assess the consequences of these productions on our environment, which can be done with a life cycle assessment (LCA). Every product has a life cycle that can be chronologically categorized into the following phases: raw materials acquisition, product manufacturing, distribution and transportation, use/re-use, and recycling/waste management. The assessment details the raw material and energy input, and the waste output that go in each of the phases. A comparative analysis of an LCA and current data on sustainable energy output, can help establish the sustainability of a product. The assessment of energy input in the life-cycle of bubble wrap and the Air Bubble Machine suggests that bubble wrap is an unsustainable product for future use. 

Raw Material Acquisition

The key component in the production of bubble wrap starts with the production of polythene, or plastic which is primarily fueled by fossil fuel or crude oil, a nonrenewable energy source. Plastic is a series of hydrocarbon monomers, referred to as hydrocarbon feedstocks. Ethane and propane, acquired from raw materials like natural gas, oil or plants, are treated with heat to create ethylene and propylene, which serve as the monomers or building blocks, to create different types of polymers of plastics (“How are Plastics Made?”). Bubble wrap is made from low density polyethylene (LDPE), which is also referred to as low density polyethylene film (LDPF) or RIC4 (Maletic).  

Each year, 240,000 miles worth of bubble wrap is manufactured and shipped all around the world. To put this into perspective, 240,000 miles of bubble wrap is sufficient enough to wrap around the Earth 10 times (Maletic)! According to ZTECH, their Air Bubble machines can produce bubble wrap that can be 1-3 meters wide with thickness between 25g/m²-300g/m². With these numbers, it can be estimated that about 9,700,000 kg - 350,000,000 kg of plastic is used per year to manufacture bubble wrap! 

In 2014, according to Plastics Europe, “3.43 MJ of electricity was needed to produce 1 kg of LDPE” (Plastics Europe). Electricity is a secondary energy source that is produced from fossil fuels primarily. Though there are renewable sources for generating electricity, they simply do not meet the demand of energy needed in the U.S.With the amount of bubble wrap produced each year, that is 33,120,299 MJ - 1,192,330,844 MJ is required to manufacture just the plastic needed for the production of bubble wrap. 

According to research done by Curtis W. Hamman, a student from Stanford University, in 2008, the process to synthesize plastics consumed “between 1.4 x 1018 J and 2.2 x 1018 J”, which is 1.4 x 1012 MJ and 2.2 x 1012 MJ. The production of plastic often uses fossil fuels that include the use of natural gas, petroleum, and coal. These are all forms of nonrenewable energy that have waste outputs that contribute to increasing global warming and have severe environmental consequences and impacts. Hamman further added to his research, “Total U.S. primary energy consumption was about 1.0 x 1020 J or 1.0 x 1014 J in 2008” (Hamman). To give a perceptive to these numbers, the production of plastic consumed “between 2.5% and 4.0% of the total U.S. primary energy consumption in 2008” (Hamman). 

It is important to keep in mind that the electricity needed for the processing and manufacturing of plastic comes mainly from fossil fuels. Fossil fuels are the primary source of energy production in the United States, accounting for about “81% of total primary energy production in 2022” ("U.S. Energy Facts Explained”). Natural gas is the most common fuel type, accounting for about 38.4% of total energy production in 2021, followed by coal at 21.9% and nuclear at 18.9% ("U.S. Energy Facts Explained”). Fossil fuels are a nonrenewable energy source, which means that once used, fossil fuels cannot be reused again. Fossil fuels emit greenhouse gasses which are terrible for the environment and also result in much habitat destruction in order to extract and produce more fossil fuels. 

Manufacturing, Processing, & Formulation 

Four steps are involved in the manufacturing of bubble wrap: resin extrusion, bubble formation, sealing, and cutting. The latter three steps are performed by the Air Bubble machine. The manufacturing and processing of bubble wrap are all sourced with energy via electricity which is a secondary energy source generated through nonrenewable fossil fuels. 

The process first begins with resin extrusion. Resin extrusion melts down and extrudes tiny plastic beads, known as resin, into a long sheet of plastic. For bubble wrap, this sheet is typically made from LDPE, which is a type of plastic known for its flexibility and durability. Resin extrusion uses “0.4 to 0.6 kilowatt hours per kilogram (kWh/kg), or 0.18 to 0.27 kWh per pound (kWh/lb)” (Kent). 

Bubble formation, sealing, and cutting are done by the Air Bubble machine. In the formation of the bubble, the extruded plastic sheet passes through the Air Bubble machine, which contains a series of rollers. These rollers press against the sheet, trapping air pockets in between the layers of plastic. As the sheet moves through the machine, the air pockets are sealed off by heat or pressure, creating the characteristic bubbles of bubble wrap. Once the bubbles are formed, the sheet of bubble wrap may go through additional rollers or heat-sealing processes to ensure that the bubbles are securely sealed and the plastic layers are bonded together. After the bubbles are formed and sealed, the bubble wrap is typically cut into smaller sheets or rolls of various sizes. The rolls are then wound onto large spools for storage and distribution (“Bubble Wrap Manufacturing Process”). Depending on the size, to complete these three steps, ZTECH’s Air Bubble Machines use between 71 kW - 170 kW to produce 800 meters - 2000 meters of bubble wrap per hour. Kilowatts (kW) is a measure of electricity needed to power any machine. According to the U.S. Energy Information Administration, it takes the following amounts of fossil fuel to generate 1 kW per hour: “coal–1.14 pounds/kWh, natural gas–7.42 cubic feet/kWh,and petroleum liquids–0.08 gallons/kWh” ("How Much Coal”). In both the production of raw material and the manufacturing of bubble wrap, it is single handedly fueled by nonrenewable energy sources, which is not sustainable for future use due to its harmful impacts to the environment.  

Distribution & Transportation

According to Sealed Air, much of their transportation of mass produced bubble wrap happens via land transportation with the use of freight vehicles, such as trucks. According to research done by Stanford University, more than 90% of transportation is fueled by fossil fuels, specifically crude oil, which accounts for almost two thirds of the oil used worldwide. Oil is another type of nonrenewable fossil fuel. Transportation worldwide accounts for 15% of global Greenhouse Gas (GHG) emissions (“Fast Facts About Energy for Transportation”). Freight vehicles consume 25% of the total US transport energy. Fossil fuels, such as oil, are the primary, if not only power source for much of the transportation of bubble wrap around the world. It is also important to understand that transportation of widely-used products don’t just happen from the warehouse to consumers, but rather have traveled much distance and used much energy to do so. It begins with the transportation of plastic to the warehouse where bubble wrap can be made. From there, processed bubble wrap travels to retail stores to be sold to consumers or can be directly disturbed to customers who have placed a custom order. Because of the highly intricate and complex transportation any product such as bubble wrap goes through, it is not possible to calculate the exact amount of energy needed to sustain it’s transportation, but it is reasonable to assume it is an amount of energy that is not sustainable to our environment or planet.  

Use, Re-use, & Maintenance 

A key characteristic of bubble wrap is its air filled pocket that resembles bubbles, hence bubble wrap. These air pockets give what was once a simple sheet of plastic, protective and insulating properties. If bubbles are not popped, bubble wrap can be reused many times and requires no energy in maintenance. 

Recycle 

Plastic that go to recycling facilities are recycled in a two-step process, cleaning and recycling. First plastic is cleaned to remove any contamination and then it is either shredded into flakes or melted down to form plastic pellets again (Leahy). Energy used in this process includes both chemical energy (fossil fuel) and mechanical energy (human labor). So even though the raw material ideally can be recycled, it is important to keep in mind that the recycling process itself is also primarily fueled by non-renewable fossil fuels. 

Plastic can be categorized via the type of resin they are made from. Hard plastic, such as bottles, containers, and jugs, are classified as “RIC #1 or #2 (RIC- Resin Identification Codes)” and are made from “polyethylene terephthalate (PET) or high-density polyethylene (HDPE)” (Leahy). However, bubble wrap is classified as a soft plastic, which has a more complicated recycling process tied to it (Leahy). 

Bubble wrap is falls under the category of RIC #4, which means it is made up of low-density polyethylene (LDPE). According to Leady, “This category and material of plastics should not be placed in curbside recycling because these plastic films are known as contaminants to the recycling system” (Leahy). Due to the soft characteristic LDPEs have, they can damage the machines that process plastic recycling by clogging them, which makes them unideal for a typical recycling plant. If LDPE or bubble wrap is placed in curbside recycling, it will be separated from acceptable recyclables and ultimately be sent to landfills, where it can take 10-1,000 years for plastic to decompose (Leahy). However, bubble wrap is still  recyclable! Leahy says, “Plastics such as bubble wrap should be grouped with other soft plastics and brought to designated drop-offs for plastic film” (Leahy). Unlike the process for recycling hard plastic, recycling soft plastic is a far more advanced and energy-intensive process that uses fossil fuels (Kikken). 

Waste Management

Though recycling seems to be the ideal situation, recycling of soft plastic such as bubble wrap is a very energy-intensive process. Recycling rates vary by location, plastic type and application. According to research and surveys, it is estimated that globally only around 9% of all the plastic waste produced is recycled ("Why Aren’t We Recycling More Plastic?"). Due to the energy-intensive process of recycling soft plastic, all the plastic that is not recycled ends up in landfills (Patoski). Even if the plastic is recycled, it would cost more to make the same product through recycled plastic compared to just making the product through new material that is easier to process. Once in landfills, few measures are taken into managing the accumulation of waste such as compaction of waste or incineration. Even these measures fail to keep up with the growing amounts of waste in landfills, so ultimately more space is acquired to expand landfills.   

79% of our plastic waste ends up in landfills or in nature. Decomposition of plastic can take 10-1,000 years, which is not sustainable for the rate at which waste is produced today.  Some 12 % of this waste is incinerated ("Why Aren’t We Recycling More Plastic?"). Though incineration can help free up space in landfills, it is “80% worse than landfills for the climate” ("Landfills Are Bad”). As much of plastic produced cannot or is not reused and recycled, bubble wrap made from plastic is not a sustainable product. 

Conclusion 

The overall energy input required in the mass production of bubble wrap  is detrimental to the environment and lacks sustainability. As demonstrated in this process, the production of bubble wrap follows a linear economy, meaning it goes from cradle (raw materials) to grave (landfills). In order to be more sustainable, it must follow a circular economy, where once used, bubble wrap can be recycled and used again to make the same product. Keep in mind that in order for the process to be completely circular, the energy source being used to power the production must also come from renewable energy sources. There are many new sustainable alternatives coming up for plastic, but it is important to be critical for the energy source being used in its production. Energy, powered primarily by fossil fuels, has directly caused higher spikes in global warming and climate change. The energy input required, compared to the overall energy consumption in the U.S. also suggests bubble wrap made from LDPE plastic is a non sustainable product. Efforts to create sustainable alternatives are currently underway, but the bulk of bubble wrap produced is via unsustainable materials such as plastic and unsustainable energy source, nonrenewable fossil fuels.

Bibliography

"2-7 LAYERS AIR BUBBLE FILM MACHINERY." ZTECH, www.ztechbubblemachine.com/product/bubble-wrap-single-screw-extruder-2-layer-bubble-film.html. Accessed 24 May 2024.

"Bubble Wrap Manufacturing Process: How Is Bubble Wrap Made?" Stanley Packaging, 20 Jul. 2015, www.stanleypackaging.com.au/blog/bubble-wrap-manufacturing-process-how-is-bubble-wrap-made/. Accessed 24 May 2024.

"Eco-profiles and Environmental Product Declarations of the European Plastics Manufacturers, High-density Polyethylene (HDPE), Low-density Polyethylene (LDPE), Linear Low-density Polyethylene (LLDPE)." Plastics Europe, 1 Apr. 2014, www.pedagogie.ac-aix-marseille.fr/upload/docs/application/pdf/2015-11/4-_eco-profile_pe_2014-04.pdf. Accessed 4 Jun. 2024.

"Fast Facts About Energy for Transportation." Stanford University, 1 Oct. 2023, understand-energy.stanford.edu/energy-services/energy-transportation. Accessed 24 May 2024.

Hamman, Curtis W. "Energy for Plastic." Stanford University, 24 Oct. 2010, large.stanford.edu/courses/2010/ph240/hamman1. Accessed 24 May 2024.

"How Are Plastics Made?" This Is Plastics, thisisplastics.com/plastics-101/how-are-plastics-made. Accessed 4 Jun. 2024.

"How Much Coal, Natural Gas, or Petroleum Is Used to Generate a Kilowatthour of Electricity?" U.S. Energy Information Administration, 20 Oct. 2023, www.eia.gov/tools/faqs/faq.php?id=667&t=6. Accessed 4 Jun. 2024.

Kent, Robin. "What's Your Process Energy Fingerprint?" Plastics Technology, 1 Mar. 2009, www.ptonline.com/articles/whats-your-process-energy-fingerprint. Accessed 24 May 2024.

Kikken, Natalie. "How to Manage Soft Plastic Recycling." CSIRO, 16 Nov. 2022, www.csiro.au/en/news/all/articles/2022/november/soft-plastics-recycling. Accessed 4 Jun. 2024.

"Landfills Are Bad, but Incinerators (with Ash Landfilling) Are Worse." Energy Justice Network, www.energyjustice.net/files/incineration/incineration_vs_landfills.pdf. Accessed 4 Jun. 2024.

Leahy, Meredith . "Is Bubble Wrap Recyclable?" Rubicon, 6 Feb. 2023, www.rubicon.com/blog/is-bubble-wrap-recyclable/. Accessed 24 May 2024.

Maletic, Marina. "A Definitive Guide to Recycle Bubble Wrap." Green Citizen, 25 Apr. 2024, greencitizen.com/blog/recycle-bubble-wrap. Accessed 4 Jun. 2024.

Packagelt Team. "The Story Behind Bubble Wrap." Packagelt, 6 Jun. 2022, www.packageit.com/the-story-behind-bubble-wrap. Accessed 24 May 2024.

Patoski, Andrej. "Why Is Most Plastic Not Recycled?" RePurpose, 22 Jun. 2019, repurpose.global/blog/post/why-is-most-plastic-not-recycled. Accessed 24 May 2024.

"Why Aren’t We Recycling More Plastic?" United Nations Development Programme, 28 Nov. 2023, stories.undp.org/why-arent-we-recycling-more-plastic. Accessed 24 May 2024.

"U.S. Energy Facts Explained." U.S. Energy Information Administration, 16 Aug. 2023, www.eia.gov/energyexplained/us-energy-facts. Accessed 24 May 2024.

Aisha Rahman

Aisha Rahman, Haleigh McCormack, Rableen Kaleka 

Professor Christina Cogdell 

DES 040A

23 May 2024 

Waste & Emissions of Bubble Wrap

Bubble wrap is the world’s best known packaging material. It started out as an attempt at funky home decor, but instead ended up revolutionizing the packaging industry. This well known packing product was developed by Alfred Fielding and Marc Chavannes in 1957, and was initially created to be 3D wallpaper. It started with “sealing two shower curtains together, and trapping pockets of air inside”(Woola 2). The wallpaper idea never took off so they then turned to the possibility of creating insulation for greenhouses instead. Unfortunately this too, never took off. This then prompted Frederick’s idea for turning the revolutionary idea into a packaging material for protecting their new line of computers. Bubble wrap provides increased protection for packages allowing for less packaging and lowered weight, which contributes to lessened shipping costs making it more appealing to businesses of all kinds. The assessment of the life-cycle of Bubble Wrap and the Air Bubble Machine through its waste and emissions suggests that bubble wrap is an unsustainable product for future packaging use. From an environmental perspective, plastic packaging products like bubble wrap are classified as single-use plastics. This means that they have potential to cause significant pollution as well as other ecological issues including the production of microplastics. Bubble wrap can be reused but this does not address the issue of its eventual destination at a landfill site.

The manufacturing process of bubble wrap releases harmful emissions further highlighting its negative environmental impact. Bubble wrap is made up of polyethylene which is known to be notoriously durable. In terms of raw material extraction, Polyethylene is originally derived from petroleum, and the production of it releases carbon dioxide (CO2), methane (CH4), as well as other greenhouse gases. There is also more waste emitted during the manufacturing process of bubble wrap as well. The Air Bubble Machine, used in the blowing process, can emit “volatile organic compounds (VOCs), and other harmful pollutants into the atmosphere. VOCs are widely common chemicals that have high vapor pressure at ordinary room temperature, implying that they can easily become vapors or gases. Human exposure to VOCs can cause short term effects such as visual and memory impairment and long term effects such as cancer and possible organ disorders. VOCs are also significant contributors to air pollution and are ground and surface water contaminants affecting marine and aquatic life. Following the blowing process, the product goes through the extrusion process where the Air Bubble Machine uses heat to shape the polyethylene. The bubbles are then formed with this heat often emitting VOCs in the process. Consequently, the manufacturing process of bubble wrap not only has significant contributions to greenhouse gas emissions, but also poses serious health risks to humans and environmental hazards, further emphasizing the urgent need for a more sustainable alternative. 

According to The Packing Solution, trucks are the most widely used vehicles when it comes to the distribution and transportation of bubble wrap. This is due to their accessibility to warehouses and availability for short to medium distance deliveries. Trains, ships, and air transport are alternate mediums of transport, however they are more commonly used for bulk transportation due to their marginally higher cost and emissions. The transportation of its bubble wrap’s materials to the manufacturing site also emits pollutants as it is transported in gas powered trucks emitting fossil fuels into the environment. Each of these methods of transportation contributes to emissions differently. Trucks often run on diesel, emitting a large amount of CO2, NOx, and particulate matter. As a major greenhouse gas, carbon dioxide traps heat in the atmosphere further contributing to global warming and an overall rise in global temperatures. Nitrous Oxide emissions from diesel trucks contribute to “... the formation of ground-level ozone, a key component of smog. This degrades air quality, particularly in urban areas with high traffic volumes.” (Packing Solution). Exposure to high levels of nitrous oxides has the ability to lead to respiratory issues such as asthma, and other more serious lung diseases. Particulate matter are small airborne particles emitted by diesel engines. These particles can penetrate deep into the lungs and eventually enter the bloodstream. According to The Packing Solution, studies show that particulate matter has shown to have led to numerous health issues such as cardiovascular and respiratory diseases linked to cancer. Particulate matter also leads to animal habitat degradation and environmental damage by settling in soil and water bodies. The combined environmental and health impacts from transporting bubble wrap emphasize the urgency for sustainable transportation solutions to mitigate these adverse effects.

Despite its widespread convenience and usage as a packing material, bubble wrap poses significant environmental challenges due to its contribution to waste and emissions in its use and reuse stage. Although it can be reused for packaging and other applications, its delicate bubbles complicate recycling efforts as it can only be reused if all the bubbles remain intact. Bubble wrap often clogs standard recycling machinery and requires specific specialized processing facilities further contributing to the complication of the decomposition process. Even when the material is eventually recycled, the environmental footprint of its production and transportation remains considerable through the factors mentioned in the transportation and production sectors. The usage phase of bubble wrap results in considerable waste due to its single-use nature. Bubble wrap is also ecologically damaging and toxic as it often takes hundreds of years to decompose. Although there are bubble wrap alternative products that can decompose within 90 days, these plastics often leech microplastics and chemicals into the environment instead which can be argued to be just as harmful, or even worse. According to Clover Packaging, there are approximately 240,000 miles worth of bubble wrap produced each year. That is enough to cover the earth's surface ten times which proves to be alarming considering the detrimental waste production associated with the product. The decomposition process of bubble wrap involves physical, chemical, and even biological processes as it is such a lengthy process. There is not necessarily a concrete process for the decomposition process of Bubble Wrap as it is often individual to its circumstances. The most common decomposition process is photodegradation. This occurs when the material is exposed to direct sunlight in landfills. Here the UV radiation begins to break down the polymer chains through an incredibly slow process. Consequently, the environmental drawbacks of bubble wrap heavily outweigh the benefits, making it a less sustainable packaging option. 

The volume of bubble wrap used globally leads to millions of tons of plastic waste annually. The challenges of recycling bubble wrap due to its material composition and contamination further complicates waste management efforts. This waste generation underscores the environmental burden posed by bubble wrap and the air bubble machine during its usage phase. During its decomposition, it breaks down into smaller microplastics that pose a dangerous threat to wildlife and their ecosystems. Decomposed bubble wrap can contaminate soil and water bodies, entering their food chain and potential impacting human health as a result. Microplastics can be ingested by marine animals which can result in digestive blockages and exposure to toxic additives used in the Bubble Wrap production process. For instance, according to Science News Explores, “... birds like fulmars have been found with plastic additives in their stomach oils, which can harm their reproductive systems and overall health”(Science News Explores). They also explain that research has proven that even smaller ocean organisms such as crustaceans can break down microplastics into nanoplastics which have the potential to cause significant biological damage. The dangers of microplastic digestion is not just an issue in animals, but also for humans. These microplastics can enter the human system through contact, inhalation and ingestion. Once they are inside the body, they can transfer to tissues and organs leading to oxidative stress, inflammation and other health effects (SpringerOpen). The long lasting nature of bubble wrap waste, along with its harmful breakdown habits highlights the urgency to find a more sustainable alternative.

In conclusion, the life-cycle assessment of Bubble Wrap and the Air Bubble Machine, reveals significant environmental concerns, underscoring its unsustainability as a future packaging material. From the waste generated during its production, to the harmful emissions released as it decomposes, Bubble Wrap and the Air Bubble Machine raise substantial ecological concerns both to the human population, and to the safety and future of our planet. For instance, the extraction of polyethylene releases large amounts of carbon dioxide and methane during production which contributes immensely to global wrarming and climate change. Furthermore, the manufacturing process of bubble wrap with the Air Bubble Machine emits volatile organic compounds. These VOCs are significant contributors to air and water pollution which can be prevented through substituting bubble wrap for a more sustainable alternative. These factors illustrate the urgent need to reconsider the reliance on bubble wrap as a safe packaging material. The broader implications of continued bubble wrap use are alarming, ultimately escalating the rate of pollution and resource depletion. As a population facing growing environmental challenges, it is imperative to adopt an alternative sustainable packing solution to bubble wrap and the air bubble machine. By shifting towards more eco-friendly practices, we can reduce waste, lower emissions, and ensure a healthier planet for future generations. 

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