ABB helps Zume offer compostable food trays

Switzerland-based ABB Robotics says it has signed an agreement to collaborate with California-based packaging maker Zume to supply robotic cells designed to boost Zume’s production of what Zume calls 100 percent compostable packaging “made from plant-based agricultural material.”

“ABB robots will automate production, enabling the scale and speed required to make Zume’s packaging a cost-effective alternative to single-use plastics,” state the two companies in a joint press release.

ABB says it will integrate and install more than 1,000 molded fiber manufacturing cells (MFCs)—including up to 2,000 robots—at Zume customers’ sites worldwide over the next five years. At full scale, the plan has “the potential to produce millions of pieces of sustainable packaging annually,” say the companies.

Zume says its packaging material is made from sustainably harvested plant material left over from agricultural production, including bamboo, wheat and straw. “Unlike plastic, plant-based material is 100 percent biodegradable and simply breaks down after use,” say the two companies, who do not mention the mechanical recycling potential of the material.

“Automating production of Zume’s sustainable packaging with ABB robots makes this a viable and economic alternative to single-use plastics,” says Sami Atiya, president of ABB Robotics & Discrete Automation. “Our collaboration showcases what is possible when organizations that are committed to pursuing a low-carbon society work together.”

Zume says its “patented and innovative” manufacturing process can produce compostable packaging for anything from food and groceries to cosmetics and consumer goods. Containers are molded from the plant material by Zume’s molded fiber cells integrated with two ABB IRB 6700 robots, with each cell processing up to two tons of agriculture material every day, creating up to 80,000 pieces of packaging.

Working with ABB, Zume says it expects to equip factories with up to 100 robotic cells each. With the automation, speed and scalability provided by the MFC, each site would have the potential to process 71,000 tons of agriculture material annually, potentially producing up to 2 billion pieces of packaging each year.

“Using ABB’s global automation experts to develop and integrate automation solutions for our customers will revolutionize packaging and demonstrate what sustainable manufacturing can look like,” says Alex Garden, chair and CEO of Zume. “This means we can offer a viable, cost-effective, compostable alternative to plastic, and help manufacturers to become more environmentally friendly.”

A pilot project has been installed by Zume and ABB Robotics at Satia Industries Limited, which the two firms describe as one of India’s largest wood and agro-based paper manufacturers. That project involves 50 manufacturing cells that will process 100 tons of wheat straw daily, creating 100 percent compostable packaging for a range of industries.

“Our work with Zume and ABB enables Satia Industries to meet and exceed the expectations of our clients for high-performing, affordable and reliable products that are sustainably manufactured and easily composted,” says Dr. Ajay Satia, chief managing director of Satia Industries. “Besides adding significant value to the company, we are able to support the planet by providing sustainable solutions to help our customers transition to more modern, reliable and customized products compared to those they use today.”

Another planned pilot installation in India will take place in cooperation with pulp and paper producer Parason. A third pilot is being planned in Texas with Lufkin, Texas-based Jefferson Enterprise Energy.