Resource efficiency thanks to innovative technologies
The packaging specialist consistently utilises technological innovations to minimize the carbon footprint of its packaging. The focus is on optimising the use of materials and the energy needed to produce a unit. Schütz shows that even the smallest material savings can have a major impact on the environment. To achieve this goal, the company vets all its processes in a comprehensive process analysis, harnesses the benefits of its high level of vertical integration and employs modern production methods. One key step to conserving resources is to reduce the weight of the packaging without compromising on quality and functionality.
An example of the successful combination of resource efficiency and performance is Schütz’s Ecobulk product family – the most widely used intermediate bulk container (IBC) in the world. Through continuous further development of the components, in particular the HDPE inner bottles and steel grids, the company has succeeded in reducing the amount of material used while at the same time improving performance even further. The company saves around 120,000 tons of CO₂ every year thanks to the reduction of raw materials in production.
Collection and reconditioning
A central element in Schütz’s recycling system is the collection and reconditioning of used packaging. With a global logistics network of 61 production and service locations, the company has the ideal infrastructure for the efficient collection of emptied packaging. This dense network not only ensures short transport routes, it also lends itself to software-supported route optimisation, which minimises CO₂ emissions and ensures the wide availability of the collection service.
After collection, a state-of-the-art reconditioning process based on advanced technology starts. Each packaging item is first analysed using AI and 3D scanning technology. Condition and any residues in the container are precisely recorded. An extensive internal database with over 400,000 different filling products is used to plan the optimum reconditioning steps. Based on these analyses, the system determines the next process steps. As part of the reconditioning process, the inner bottle of the IBC is replaced, while the steel grid and pallet are cleaned, checked and repaired if necessary. These components are designed in such a way that they can be used for several packaging cycles, which significantly increases the service life of the packaging and reduces the need for new raw materials.
Up to 100 kilogrammes of CO₂ can be saved per packaging cycle by reconditioning IBCs in line with the Recobulk programme. Customers benefit from the easy, customer-centric Schütz Ticket Service and the efficient disposal of used packaging. Even the smallest quantities or IBCs from compatible third-party brands are collected.
Plastics recycling: circular economy in perfection
As part of the overall recycling concept, Schütz operates state-of-the-art recycling centres that process the HDPE material after shredding and cleaning in various mechanical preliminary stages to produce high-quality, odourless and homogeneous pellets. This flows into the production of new packaging components. In this way, recycled material is turned into high-performance pallets, corner guards and other components such as flaps or acid protection inserts.
In the Green Layer series packaging, the recycled pellets are used for the middle layer. By using state-of-the-art 3- and 6-layer extrusion systems, Schütz is able to significantly increase the proportion of recycled material in the products: the middle layer of the IBC inner bottles, jerrycans and plastic drums in this product range consists of high-quality, natural-coloured regranulate. The inner and outer layers are made of HDPE virgin material meaning that the contents only come into contact with new material.
This process guarantees the highest safety and quality standards, especially for hazardous goods packaging. Together with the pallets and corner guards made of recycled plastic, the total proportion of recycled material in the Green Layer IBCs can be increased to up to 70 per cent. The increased use of recyclate significantly reduces CO₂ emissions per packaging. The use of recycled pellets in green layer packaging enables additional savings of up to 6.8 kilogrammes of CO₂ per IBC and up to 3.8 kilogrammes per plastic drum.
Advantages of Green Layer packaging by Schütz
- Exclusive use of Schütz Green Layer regranulate obtained from meticulously controlled, in-house production
- State-of-the-art multi-layer extrusion ensures that this material is used only in the middle packaging layer
- The recyclate has a uniform colour and is practically odourless thanks to several successive processing steps
- Guaranteed conformity for the packaging application
- Same standard specification and same level of hazardous goods approval as the corresponding Schütz packaging made from 100% HDPE virgin material
- Hazardous goods packaging undergoes regular, randomised testing
Sustainability through joint action
Sustainability can only be achieved effectively if everyone involved along the value chain actively works together. This is why customers and users play a decisive role in Schütz’s Green Lifecycle Management. Their responsibility begins with the return of empty packaging through the Schütz Ticket Service. The more used IBCs, drums and jerrycans that are returned to the cycle, the more effectively Schütz can produce high-quality recyclate and use it in new packaging. This participation is essential in order to close the material cycle and ensure the long-term availability of recycled material. Looking ahead, it is clear that the systematic expansion of the circular economy will continue to become increasingly important.
