Innovation: PulpWorks tilts at retail blister packaging

SAN RAFAEL -- Product quiz: What's been on retail shelves for 50 years, has a life span of 100,000 years and causes 50,000 visits to the emergency room a year?

The answer is the blister pack, the ubiquitous and widely hated polyvinyl chloride (PVC) clear plastic packaging that entombs just about everything from AA batteries to Zippo lighters.

"Consumers don't like it, and along with expanded polystyrene (EPS), it's terrible for the environment," said Paul Tasner, an outspoken opponent of both. He's come up with a compostable, all-paper alternative and formed PulpWorks Inc. to take it to market.

[caption id="attachment_64276" align="alignright" width="283"] EO Products of San Rafael is testing its hand sanitizer spray bottles in PW-Pack retail packaging.[/caption]

His PW-Pack is made of recycled paper molded like an egg carton to cradle the product, with a printed, branded, die-cut face card for retail display.

The PW-Pack has a lot going for it. It's often less expensive to manufacture, warehouse and ship than PVC and EPS packaging. EPS foam is most commonly known by the brand name Styrofoam. PW-Pack assembles rapidly, provides cushioning superior to plastic, is static-free and its production and disposal doesn't release chemicals fingered for human-caused climate change. Easy and safe to open, it degrades quickly when composted.

But what it's not is even more significant. Seven billion pounds of PVC are discarded every year in the United States. Production and incineration of PVC is a major source of the carcinogen dioxin in the environment, according to the U.S. Environmental Protection Agency. Styrene, a chemical in EPS, can migrate into human tissue from containers and is "reasonably anticipated to be a human carcinogen," according to the U.S. Department of Health and Human Services. EPS foam containers also pollute both land and ocean.

The price points of such packaging perpetuates their use, according to Mr. Tasner.

"The chemical and manufacturing industries have been honing formulations and production methods for decades," he said. "They've worked out any bugs and brought the costs down relatively close to zero. These are very difficult industries to challenge on price points. Manufacturers are pretty well locked in to whatever saves them money."

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