Sustainable reusable packaging specialist Schoeller Allibert and Dutch brewery Royal Grolsch are taking a further step towards a circular economy with their latest joint project: sustainable pallets made from recycled plastic.
The Royal Grolsch brewery in Enschede in the Netherlands combines centuries-old craftsmanship with a forward-thinking approach to innovation. To reach its sustainability targets and address its operational demands, Grolsch has partnered with Schoeller Allibert. The packaging specialist is an expert in material innovations made from recycled plastics – the companies share the common goal of a functioning circular economy.
Old pallets, new problems
The current keg pallets no longer met the company’s needs. Their heavy weight drove up transportation costs and related CO2 emissions, while outdated molds made them harder to source and less reliable. But it wasn’t just about logistics and function – Grolsch also wanted to achieve its ambitious sustainability goals.
“Replacing these pallets was an excellent occasion to consider their environmental implications,” says Joost Nawijn, Packaging Material Development Specialist at Koninklijke Grolsch. “That’s why we wanted a lighter pallet made from recycled material, thus a more sustainable solution.”
Solution for the circular economy
No big task for Schoeller Allibert: the company delivered a tailor-made keg pallet that meets all the brewery’s requirements. The new load carriers are made of 100 percent post-consumer recycled plastic and are also 12 kilograms lighter than their predecessors. Grolsch can therefore significantly reduce the material used.
How has Schoeller Allibert achieved this? The designers achieve the reduced weight of the pallet with the special honeycomb structure, but also through a different production technique. Instead of using a low-pressure process, the experts manufacture the keg pallets using a high-pressure injection molding process. The recycled plastic comes from post-consumer material – i.e. used bottles and packaging that are collected, sorted, cleaned and processed into new products. On the other hand, old pallets (post-industrial material) are also used. This reduces emissions by 83 percent compared to pallets made from virgin materials. Once the load carrier has reached the end of its life cycle, Schoeller Allibert takes it back and recycles it. An example of a functioning circular economy.
Optimum handling, individual design
The new pallet offers even more features for the brewery’s day-to-day operations. The honeycomb structure makes it lighter and stronger. Forklift trucks can also pick it up more easily thanks to the smoother fork entries, which means that hardly any damage occurs. The stackable design enables a seamless transition between old and new pallets, allowing the user to use both versions in parallel. In addition, the stackability reduces the space required for return transportation, which also reduces CO2 emissions – as fewer trips are required.
The new pallets have been in use since January 2025. The close cooperation between Schoeller Allibert and Grolsch resulted in a perfect solution in which improved utilization function, reduced CO2 emissions and cost savings go hand in hand.
“Our intelligent solutions are tailored to the requirements of the Grolsch brewery,” summarizes Vincent Vos, Head of Design at Schoeller Allibert. “To achieve this, our experts listen to what the customer needs, develop a solution and test it until it is successful.”
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