30% PCR STRETCH FILM HELPS ADHESIVES MANUFACTURER ACHIEVE SUSTAINABILITY GOALS & EPR COMPLIANCE
Situation
A leading manufacturer of high-performance adhesives and bonding solutions was wrapping thousands of pallets annually with conventional 65 ga stretch film.
Their current process ensured load stability but came with higher film usage and escalating costs. With sustainability goals and Extended Producer Responsibility (EPR) regulations on the horizon, the company needed a solution that would:
- Reduce material consumption without compromising load integrity
- Support circular economy initiatives through post-consumer recycled (PCR) content
- Deliver measurable cost savings at scale
Solution
Through Group O’s SMART Audit®, we evaluated multiple film options and tested a high-performance 49 ga stretch film with 30% PCR content against their existing 65 ga conventional film. Key factors such as force-to-load, film stretch performance, pallet coverage, and cost per pallet were analyzed.
The audit revealed that the PCR film not only matched but in some cases exceeded the performance of the conventional film while using significantly less material per load. This allowed the client to downgauge from a 65 ga conventional film to a 49 ga 30% PCR film without sacrificing performance - achieving sustainability and cost targets simultaneously.
Results
- Material Reduction: Reduced overall film usage by 24% by switching to the 49 ga 30% PCR film, achieving the same load performance with less material.
- Virgin Plastic Reduction: Cut reliance on virgin plastics by 47%, significantly lowering environmental impact and supporting circular economy goals.
- Sustainability Impact: Integration of 30% PCR film supported corporate sustainability commitments, reduced reliance on virgin resin, and contributed toward EPR compliance.
- Cost Savings: Using 30% PCR film is projected to reduce annual costs by approximately 5% compared to the current material.
- Performance Gains: Increased force-to-load ensured secure shipments, minimizing risk of product damage in transit.
Bottom Line: By converting from a 65 ga conventional film to a 49 ga 30% PCR stretch film, the manufacturer reduced material waste by nearly a quarter, lowered packaging costs by 5%, and took measurable steps toward achieving sustainability goals - all while maintaining the same high level of pallet security.
Feature / Metric | Impact / Benefit |
| Film Gauge: | Downgauged without sacrificing performance: 65 ga to 49 ga |
| Material Usage: | Reduced overall film usage by 24% |
| Sustainability: | Supports EPR compliance and circular economy |
| Annual Spend: | 5% cost savings |
| Load Stability: | Maintains pallet integrity, reduces transit risk |
| Virgin Plastic: | 47% reduction in virgin plastics |
