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Good practices in CP: 80. Creating a closed loop of paper tubes for film and bags, through a system of collecting them from customers and reusing them in the production process (ARTFOL)

Written By Polski Ruch Czystszej Produkcji on czwartek, 27 października 2022 | 13:25

photo by ARTFOL


Good practices and investments related to Cleaner Production

Example No. 80
Creating a closed loop of paper tubes for film and bags, through a system of collecting them from customers and reusing them in the production process

Company:
ARTFOL Spółka z ograniczoną odpowiedzialnością sp.k., Piotrków Trybunalski

Industry branch: plastics
Main products: LDPE and HDPE films, LDPE and HDPE film packaging, bags, LDPE, HDPE and PP film bags

Resources in question:

  • Materials
Pollution, waste in question:
  • Waste
Cost (implementation of good practice): Low
(about PLN 1,000 – the cost of purchasing 5 wooden boxes marked with the company's logo, to be set up at customers' sites)

Description of the problem:
 
Among other products, the company produces films and plastic bags, which are wound on paper tubes. At customers’ sites, empty tubes became waste after the wound products were used up, despite the fact that most used tubes are reusable.
The steadily increasing cost of buying new paper tubes and the limited possibilities of sending used tubes for recycling (since they are produced from paper with an adhesive) prompted the company to organize a closed loop. While the use of empty tubes internally was not a problem, the organization of tubes collection and storage by customers remained problematic.

Applied solution:
 
The company has pilot-selected three of its largest customers, to whom the goods are delivered in rolls (wound on tubes). They were offered to use wooden boxes purchased by ARTFOL, into which workers would deposit used tubes. The collection is carried out by ARTFOL when the goods are delivered (using previously empty return transport, which reduces environmental impacts and virtually reduces the cost of collecting the tubes to zero). Transferring the tubes back to ARTFOL minimizes waste on the customer's side and enables a reduction in the use of materials for tubes (less purchasing needs). It also makes it possible to keep the price of goods competitive.

The company additionally intends to place an inscription on the tube: “RETURN TUBE – RECEIVER ARTFOL Piotrków Trybunalski (raising environmental awareness among employees and customers, building and spreading good ecological habits).

Obtained benefits and effects of the implementation:

The project has been implemented recently (2022), but the following effects have been estimated based on measurements to date (concerning three clients):
  • Reduction in the amount of tubes purchased by about 95%, which translates into about 2,280 pieces/year (i.e., about 10,260 kg/year) less waste generated on the customer side
  • Savings from reduced purchase of new tubes: about PLN 54,700/year, according to Q3 2022 prices (payback period: about 10 days)
Since the above calculations are based on the effects calculated for three customers, they may increase if more customers are interested in this solution. The company also plans to purchase a tube-cutting machine, which will give it more flexibility and the ability to reuse custom-size tubes.

An important aspect of this activity will be the competitive advantage that the tube recovery service will provide. For example, the company has begun discussions with a potential customer who approached it precisely because of its ability to take back the tubes (to reduce costs and implement its own environmental policy).



Tube – empty (material) and with wound film (product)
photo by ARTFOL

 

Wooden box for empty tubes to be returned (to be set up at the customer's site)
photo by ARTFOL
 
 
Source:
  • Report on the Cleaner Production Project No. 9ind.817, developed within the framework of the Cleaner Production Academy at ARTFOL Spółka z ograniczoną odpowiedzialnością: "Creating a closed loop of paper tubes for film and bags, through a system of collecting them from customers and reusing them in the production process"

 
Polish version:



This material has been subsidized by the National Fund for Environmental Protection and Water Management. The Polish Cleaner Production Movement Association is solely responsible for its content.








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