Pilot 3 / Value Chain 2: Reusable Plastic Packaging

Reusable packaging systems can increase sustainability through recycled materials and closed-loop reuse, but the sector faces barriers such as inconsistent material quality, dependency on suppliers, limited data, logistical inefficiencies and the need to optimise packaging design for reuse, repair, cleaning and transport.

CSSBoost supports the development of a packaging configurator that helps customers design sustainable packaging, reduce waste and optimise material use. The value chain focuses on reusable packaging and twinwall sheet manufacturing, including the use of recycled or more sustainable materials.

Planned activities include full value-chain analysis, tool selection, prototypical implementation, interim feedback and sustainability assessment.

Percentage of recycled material used: target 30% short term and 50% long term.

Production scrap/reject rate: target ≤2% reduction.

Energy consumption per unit: target 15% short-term and 20% long-term reduction.

Damage rate in transit.

Return rate of boxes.

Turnaround time for repair and cleaning.