ABB and Zume accelerate the elimination of single-use plastic

2021: Using ABB robots to produce biodegradable packaging

On November 17, 2021, ABB announced that its Robotics division signed a cooperation agreement with  the Scaliforni company Zume, a global supplier of technologically biodegradable packaging. ABB will supply robotic cells that will allow Zume to produce environmentally friendly biodegradable packaging made from plant-based agricultural raw materials around the world, helping to reduce dependence on single-use plastic.

According to the information company, less than 10% of the 380 million tons of plastic produced annually in the world is processed. (Environment Programme UN). Packaging of plant materials can significantly reduce the number plastic sent to landfills and into the oceans.

Over the next five years, ABB will install integrates more than 1,000 productions robotic molded fiber (MFC) cells, including up to  2,000 at robots Zume customer sites around the world. ABB leverages the capabilities of its management programs and automation experts from its network of global solutions centers. This will provide production with the scalability, modularity and speed needed to launch technology complexes that can produce millions of units of environmentally friendly packaging annually. Financial details of the agreement were not  disclosed.

Manufacturers are facing increasing pressure from consumers and policymakers  to find alternatives to single-use plastic packaging. Packaging should be environmentally friendly, easy to form and as cost-effective as plastic. Zume packaging material, according to the company, is made of environmentally friendly plant material left over from agricultural production, including bamboo, wheat and straw. The creation of a package of plant material consumes significantly less water and energy and reduces CO₂ emissions compared  to the production and disposal of plastic packaging. Unlike plastic, plant-based materials are 100% biodegradable and simply degrade after use.

"Zume's automated production of environmentally friendly packaging with ABB robots makes it a viable and cost-effective alternative to single-use plastic.  With Zume, we have the ability to remove trillions of pieces of plastic from the global market, preserving limited resources and maintaining a low-carbon world. Robotic automation expands opportunities by making the world greener through more efficient production that reduces energy consumption, emissions, and production waste, " noted Sami Atiya, president of ABB's Robotics and Discrete Automation business.

Zume has developed and patented a technological manufacturing process that allows you to create biodegradable packaging for anything from food and groceries to cosmetics and consumer goods. The containers are molded from  plant material using Zume cells for the production of molded fiber integrated with two robots IRB 6700 from ABB. Each cell processes up to two tons of agricultural raw materials daily, producing 80,000  units of environmentally friendly packaging. In collaboration with ABB, Zume plans to install up to 100 robotic cells in each factory. With the automation, speed and scalability that production cells provide, each plant could handle 71,000  tons of agricultural raw materials per year, potentially producing up to two billion packages per year.

"According to our estimates, by 2050 there will be more plastic in the oceans than fish, so it is extremely important to abandon single-use plastic. Involving ABB's international automation experts to develop and integrate automation solutions for our customers will make changes  in packaging and demonstrate what sustainable manufacturing can be like. The flexibility and scalability of ABB robots provides an efficient, automated manufacturing process. This means that we can offer a viable, cost-effective biodegradable alternative to plastic and help manufacturers become more environmentally friendly, " noted Alex Garden, chairman and chief executive officer of Zume.

Zume and ABB implemented a pilot project at Satia Industries Limited,  one of India's largest producers of wood and paper based on agricultural raw materials. The companies created a plot of 10 production cells that will process 20 tons of wheat straw daily, producing 100 percent biodegradable packaging for various industries.

"Our work with Zume and ABB enables Satia Industries to meet and exceed the expectations of our customers for high-performance, affordable products that are manufactured in accordance with the principles of sustainable development and easily decompose. We can support the planet by providing environmentally sound solutions that help our customers transition to more relevant and individualized products, " said Dr. Ajay Satia, CEO of Satia Industries.