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Driving a Circular Economy through Reusable Plastics

Lucas van der Schalk, CEO, CorplexLucas van der Schalk, CEO
Most businesses have a preconceived notion that plastic is more dangerous to the environment and produces higher CO2 than cardboard boxes. But in truth, it’s the opposite. Organizations focus on reducing their carbon footprints but continue using cardboard for packaging. Compared to reusable plastic boxes, cardboard ones are single-use products. Even when recycled, cardboard packaging releases 380 to 450 Kg of CO2 per ton, significantly more than the 180 kilos produced during plastic recycling.

Enter Corplex, an organization providing compelling alternatives to conventional cardboard with its environment-friendly, reusable plastic packaging solutions. Its portfolio comprises hygienic packaging, transit packaging and storage, and reusable plastic boxes, ranging from small e-commerce boxes to large foldable containers. These solutions facilitate a circular economy across automotive packaging, industrial manufacturing, logistics, retail, and pharmaceutical applications. Corplex’s core business expertise, from raw material to recycling, and ability to capture essential insights from every project enables it to consistently develop efficient and complete solutions for every packaging need.

“The beauty of our packaging is it can be returned to us at the end of its lifecycle, and we can repurpose or recycle it to make a new packaging unit for the same application,” says Lucas van der Schalk, CEO of Corplex.

Simultaneously, Corplex provides various lightweight and easily customizable or printable plastic board structures that are highly resistant to chemicals and microbial growth. These offerings can be used to construct reusable packaging for different industries. From a manufacturing standpoint, Corplex’s plastic sheets use prime or recycled material formulations of polypropylene and HDPE thermoformed sheet, ideal for rigid packaging that collapses for its efficient return. Alternatively, it does bespoke work for clients looking to develop customized packaging for their specific needs.

Typically, cardboard-based packaging takes up space on freight regardless of holding valuable products, driving the need for multiple logistics trips to reacquire packaging materials for recycling. Corplex bypasses this issue with its foldable solutions that can easily be compacted for easy storage and transportation. This capability is pivotal in strengthening the movement toward a circular economy where businesses maintain, reuse, remanufacture, and recycle materials to create more value for future generations.

  • The beauty of our packaging is it can be returned to us at the end of its life cycle, and we can repurpose or recycle it to make a new packaging unit for the same application

Recently, Corplex developed a reusable packaging solution compatible with automated lines for a global supplier of LED TVs. The solution is made of a thermoformed pallet and lid and a polypropylene sleeve with a wide opening in the front that would allow for a robot to take the front and rear parts of a TV screen and assemble them on a production line. The innovation’s uniqueness resides in the potential to create a sleeve that would work with automated lines as well as a number of various pallets and lids.

The main asset was that Corplex was able to design a multi-material solution made of robust yet lightweight and very easy to maintain materials. Some of the current Corplex pallets and lids have been in use for about ten years, proving their quality and sturdiness.

Similar successes exemplify Corplex’s competencies in providing reusable and recyclable solutions that can stand the test of time and support the burgeoning movement toward a circular economy and carbon reduction. In the future, Corplex intends to continue helping companies with its reusable packaging solutions and reduce the impact of businesses on the environment. The real benefit of the reuse and recycle model is that the customer can be protected from material price hikes by returning damaged packaging, which is then recycled back into new units without acquiring new raw materials at ever-increasing prices.

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Corplex

Company
Corplex

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Lucas van der Schalk, CEO

Description
Corplex is an organization poised to provide environment-friendly reusable plastic packaging solutions for the circular economy in applications such as, automotive packaging, construction, automotive component, retail and pharmaceuticals. Corplex offers packaging solutions such as hygienic packaging, transit packaging and more.

Corplex News

Corplex and partners produce reusable delivery boxes for mobile phone handsets

Corplex, Packeta, and Slovak Telekom are serializing their production of reusable e-commerce boxes for delivering mobile phone handsets directly to consumers’ doorsteps – also incorporating QR technology for product tracking and inventory management.

With production taking place at Corplex’s production site in Hurbanovo, the boxes feature fully closed, die-cut edges and a microperforated area for labels, which are said to facilitate easy label removal without leaving any residue. All printing takes place in-house with a laser printing machine, Corplex explains.

Each pack also features a QR code to track the product and manage inventory. From the project pilot, the companies have incorporated the process of scanning each code, uploading it to an Excel spreadsheet, and checking for duplicates during serial production.

They add that operators can use macros to check for missing QR codes and account for waste generated in the production process.

The final packaging design is fully patent-protected in the EU and seeks to hold the product components in place to prevent loss or damage in transit.

By serializing production, the companies intend to meet customer expectations and unlock more sustainable e-commerce deliveries for the telecommunications sector. The project’s pilot apparently proved that as many as 5,791 mobile phones could be delivered in reusable and recyclable AkyPak boxes.

Deutsche Telekom, Vodafone, Orange, and Telefónica are all said to be interested in the system, which previously won the 2023 Innovation Project of the Year. Corplex, Packeta, and Slovak Telekom aim to produce 24,000 pieces of reusable packaging starting his month.

A similar solution comes from reusable packaging and retail tech start-up no-boxx. The company unveiled its reusable pouch packaging and tracking application last year, with its sights set on less single-use packaging waste, lower carbon emissions, and optimized traceability in e-commerce deliveries.

Furthermore, Rhinopaq and Circular Logistics partnered with Riese & Müller to deliver its e-bikes and small components in reusable plastic packaging – a move expected to reduce an initial 905 tonnes of cardboard waste every year.