Amcor R&D progresses sustainability agenda during COVID-19

While globally, we are focused on helping our customers to meet increased consumer demand, our work on our longer-term sustainability and innovation agenda is progressing at pace. With 1,000 colleagues in R&D, the function is demonstrating resilience, flexibility and collaboration in the face of the current challenge, and an unwavering commitment to better packaging solutions for people and the planet.

William Jackson, Chief Technology Officer for Flexibles, and Brian Carvill, VP Research, Development and Advanced Engineering in ARP, share how R&D teams across Amcor are adapting to maintain (virtual) engagement with customers, keep innovation trials on track; and, stay connected while working remotely.

Progress with product launches and trials

With in-person interactions not possible in most locations, Amcor R&D teams are using alternate means to stay connected with customers.

For example, ARP’s Industrial Design team hosted a virtual “Eight Hour Month” session with a major global customer to re-design a PET bottle for a popular cold coffee beverage.

“While this isn’t the first time we’ve used design tools virtually, it’s a great example of the flexibility of the team and their ability to stay connected and make progress towards our customers’ objectives,” said Brian.

Teams across Amcor are running virtual meetings with customers, bringing together customer brand teams, R&D teams, fillers and closure suppliers, and outside design agencies with Amcor commercial, industrial design, computer-aided design (CAD), and product development experts. During the session, teams often go from more than a dozen potential designs to four – with the goal of moving to rapid prototyping of two preferred designs.

Amcor R&D colleagues are also progressing with new product launches and development trials.

“We’re working with major customers to launch new product in late August, early September. We’re making blow molds using our capability in Manchester, Michigan, and plan to run the lab trials in April so we are still on our agreed launch timeline,” said Brian.

Overall, Amcor’s pilot plant and lab teams are working to maintain critical development trials. While practicing good hand hygiene and social distancing, they haven’t missed a beat.

“When some team mates were self-quarantined, people from the innovation team volunteered to keep the blow molding machines running,” said Brian.

Continued strides towards our 2025 pledge

In addition to existing product trials, Amcor continues to test new innovations in sustainability that are moving closer to customer trials and commercialization. Pilot facilities and analytical labs are accessible, so teams can continue to run trials of new materials and formats. The global team is also writing patents to protect IP relating to Amcor’s sustainability innovations.

To facilitate faster innovation and maintain momentum toward its pledge to develop all Amcor packaging to be recyclable or reusable by 2025, the R&D team in Europe is working with operations and others to develop the plans for an upgraded innovation and customer experience center in Ghent, Belgium.

“Our upgraded innovation and customer experience center in Ghent will accelerate packaging concepts through collaboration, rapid prototyping and hands-on research. We are working with an architect and cross-functional Amcor team to take the best from our innovation centers around the world and upgrade our center in Europe,” said William.

Innovating to support the COVID-19 relief effort

In partnership with manufacturing colleagues, Amcor is adapting its operations and materials to make critical healthcare packaging and personal protective equipment. For example, the company has been making general protection masks in sites in China and is donating funds and products to emergency services, local hospitals and organizations in local communities, worldwide.

Innovation also includes repurposing current packaging products.

The Flexibles R&D teams are looking at how to adapt sachets usually used for ketchup and other condiments for new applications, like single-serves of hand sanitizer. In LATAM, R&D experts are blow molding PET for face shields for healthcare professionals.

Adapting to working from home

Fortunately, CAD software can be used at home, so the Industrial Design team is continuing to develop technical drawings and share them with customers via online collaboration tools.

With productivity levels high and new products being developed for customers, you almost wouldn’t know there’s been disruption to usual work routines.

“Mark Woloszyk in our Advanced Engineering team adapted our toolbar in CAD so that most functions could be completed at home without VPN access. Despite the unusual working conditions, we are near an all-time high for the number of drawings completed in March,” said Brian.

To stay connected as a team – and keep spirits up while working remotely – R&D colleagues are exchanging photos of their work environments, families and, of course, pets.

“I’m grateful for our people in R&D and across Amcor for their resilience, flexibility and dedication during this unprecedented time. When this is over, we will come out stronger, better prepared for crises, and closer as a team. We will also have a greater appreciation for what Amcor colleagues do every day, and the importance of our products to the protection and well-being of our community,” said William.