Mosca GmbH, a specialist for strapping machines and materials, presents the SoniXs P7-Connect, the next generation for fully automated operations. The new machine succeeds the SoniXs MP-6 and offers extended functionalities.
The SoniXs P7-Connect sets new standards in the entry-level segment of automated strapping. The strapping machine has been specifically developed for seamless integration into fully automated production lines. It is based on state-of-the-art technology for strapping cartons or bundling products in a production line. It offers customers reliability and focuses on connectivity and Industry 4.0 capability with its cutting-edge control system.
The highlights of the SoniXs P7-Connect
“With the SoniXs P7-Connect, we offer our customers a future-oriented entry into the world of fully automated and digitalised strapping,” explains Andreas Ding, Senior Innovation Manager Sales at Mosca. The machine has three key features that set it apart from its predecessor MP-6 and further equipment in the market segment. For example, the switch from circuit board to intelligent controls offers greater functionality, increased modularity, and maximum process reliability. It resembles the SoniXs TR-Connect in terms of control technology, but at a significantly more attractive price.
The SoniXs P7-Connect is network-compatible and enables data transmission via mobile communications directly to the cloud, from where the recorded information can be integrated into ERP systems and reused. The WebHMI is available to customers as standard for intuitive operation. An optional WLAN module makes it quickly and flexibly accessible. Thanks to the new interface options and extended access via the WebHMI, customers can establish comprehensive settings and configure interfaces individually. The machine’s IoT capability also ensures high data transparency and improves availability, even beyond the actual production site.
The proven user-friendliness has been retained in the new generation. Among other things, it features the integrated spool slider for easy material access as well as the automatic threading process, which further increases ease of use.
Technical specifications and variants
The core of the SoniXs P7-Connect is the proven and highly efficient standard 7-SoniXs sealing unit. The energy-efficient SoniXs ultrasonic sealing technology is one of Mosca’s key competencies and enhances the quality and performance of the strapping process. To ensure maximum flexibility, the machine supports PP straps with a width of 5, 8, 9, or 12 mm. The SoniXs P7-Connect will be available in the standard frame sizes 600×600 mm, 800×600 mm, and 1000×800 mm.
Powered transport tables in belt or roller versions, which are designed for automated product feeding, enable the integration into automated lines. The machine has all necessary interfaces, including the highly flexible OPC UA interface, to ensure smooth machine and system communication and enable customers to use data-based solutions.
With the launch of the SoniXs P7-Connect, Mosca underlines its role as an innovation leader, as Andreas Ding confirms: “We provide our customers with technologies that already meet the upcoming market requirements for digitalisation today”.
Sustainable packaging is becoming an essential consideration for logistics and supply chain professionals. As businesses seek to balance cost efficiency with environmental responsibility, the adoption of sustainable packaging materials offers a viable solution. Understanding the factors that drive this transition, as well as the best strategies for implementation, is crucial for optimizing both ecological impact and operational efficiency.
Factors Driving the Adoption of Sustainable Packaging
Several key factors contribute to the growing emphasis on sustainable packaging within logistics. One of the most significant is increased consumer awareness. Customers are now more conscious of environmental concerns and demand ecofriendly products and packaging. Companies that integrate sustainable packaging materials into their supply chains can enhance brand reputation, improve customer loyalty and gain a competitive edge.
Regulatory pressures also play a crucial role. Governments worldwide are implementing stricter policies on packaging waste, requiring businesses to adopt sustainable solutions. Compliance with these regulations ensures companies avoid legal penalties while demonstrating corporate social responsibility.
Economic benefits further reinforce the shift toward sustainable packaging. While initial investment costs may be higher, many sustainable packaging materials offer long-term savings through reduced material waste, lower disposal costs and improved supply chain efficiency. Lightweight, biodegradable and recyclable materials can decrease shipping expenses, making sustainable packaging a financially viable choice.
Choosing the Right Sustainable Packaging Materials
Selecting the appropriate materials for sustainable packaging involves evaluating various factors, including durability, cost and environmental impact. Biodegradable materials, such as cornstarch-based plastics and molded fiber, decompose naturally and reduce landfill waste. Recyclable options, like cardboard and paper-based alternatives, help establish a circular economy, minimizing resource consumption.
Compostable packaging is another viable choice, offering an ecofriendly solution that breaks down into nontoxic components. Additionally, reusable packaging, such as durable crates and bulk containers, reduces waste while streamlining logistics operations. Businesses must assess the compatibility of these materials with their supply chains to maximize sustainability benefits without compromising functionality.
Strategic Implementation of Sustainable Packaging
To successfully integrate sustainable packaging materials into logistics and supply chains, companies must follow a strategic approach. First, conducting a life cycle assessment (LCA) helps determine the environmental footprint of current packaging materials. By analyzing resource consumption, emissions and waste generation, businesses can identify areas for improvement and make informed decisions about material selection.
Collaboration with suppliers is another critical step. Working with sustainable packaging manufacturers ensures access to high-quality materials that meet environmental standards. Additionally, fostering partnerships with third-party logistics providers (3PLs) that prioritize sustainability can streamline packaging integration and optimize supply chain operations.
Technological advancements further enhance the feasibility of sustainable packaging adoption. Innovations such as smart packaging, which incorporates tracking sensors and biodegradable coatings, improve efficiency while reducing waste. Companies should explore emerging technologies to stay ahead of industry trends and drive sustainability efforts.
Balancing Sustainability With Operational Efficiency
While the benefits of sustainable packaging are evident, businesses must ensure that adoption does not compromise operational efficiency. Packaging materials should maintain product protection and durability to prevent damage during transit. Conducting real-world testing and pilot programs can help evaluate the performance of sustainable alternatives before full-scale implementation.
Optimizing packaging design also contributes to operational efficiency. Reducing excess material usage, improving stacking capabilities and utilizing space-efficient designs lower transportation costs and decrease carbon emissions. Automation in packaging processes further enhances efficiency, allowing businesses to scale sustainability initiatives without increasing labor costs.
Conclusion: A Proactive Approach to Sustainable Packaging
As logistics and supply chain professionals navigate the transition toward sustainability, strategic implementation of sustainable packaging materials remains essential. By addressing consumer demand, regulatory requirements and economic advantages, businesses can create packaging solutions that align with environmental goals and operational needs. Through careful material selection, supplier collaboration and technological integration, companies can reduce waste, lower costs and enhance brand value while contributing to a more sustainable future.
Retail brands are increasingly recognising the power of returnable transit packaging (RTP) to improve their sustainability credentials and slash logistics costs.
With rising labour, fuel and single-use packaging costs, today’s retailers seek solutions that deliver lower transport and handling costs. In response, Loadhog has developed Dolly Max, a next-generation rolling container system. A modular solution with versatility, Dolly Max enables retailers to adapt to the fluctuating needs of their supply chains.
The Dolly Max transport dolly is compatible with a whole host of container configurations for segregated or loose bulk goods, as well as traditional cardboard boxes. This makes it the ideal substitute for roll cages, shrink-wrapped pallets and pallet shippers – all of which have disadvantages. Roll cages can prove heavy to manoeuvre, often have inefficient brakes and can feature sharp metal touchpoints. Shrink-wrapped pallets, meanwhile, are not environmentally friendly and, along with pallet shippers, require separate handling equipment that takes up valuable shop-floor space.
By combining the Dolly Max with Loadhog containers – whether attached-lid, bail-arm or collapsible – and Loadhog’s award-winning Pallet Lid, retailers achieve a secure end-to-end handling system that is almost infinitely configurable. An eco-friendly alternative to stretch wrap, the reusable Pallet Lid features retractable straps and an integrated tensioning mechanism to secure the load. In this way, the Dolly Max provides the ultimate RTP solution, completely eliminating the need for single-use packaging.
The Dolly Max system is also ideal for handling ‘uglies’, with items such as cushions and footballs capable of being transported – and even presented to consumers – within a foldable sleeve unit. The ergonomic, one-touch sleeve lock has a large access point for safety shoes, and enables rapid system construction. Various sleeve sizes can be topped with Loadhog’s Stacking Tray, creating a secure platform for adding containers to form a mixed load.
Savings for Harvey Nichols
Capable of being wheeled directly onto the shop floor, dollies significantly reduce the need for additional handling, thereby easing labour issues. For example, by using Loadhog’s Pally 86 dolly, luxury department store Harvey Nichols has been able to pick goods from the warehouse shelf and not touch them again until the shop floor, removing no less than four touchpoints. The solution has also eliminated a significant amount of one-trip packaging from the retailer’s operation, reducing waste to landfill.
Features of the Dolly Max include an innovative, one-touch brake mechanism with easy access, which is both faster and more ergonomic than the castor brake found on most roll cages. The dollies can be linked and moved together to reduce marshalling time in distribution centres. The Dolly Max has excellent ground clearance and manoeuvrability, making it easy to navigate from delivery vehicles at the roadside into retail stores. In addition, the tare weight and footprint of the system enables use on all vehicle types, including smaller sprinter vans. Labelling, tracking and branding options are also available to safeguard both the packaging assets and the goods.
Of course, the Dolly Max system ticks all the boxes when it comes to sustainability, supporting companies to reduce their carbon footprint. The solution features recycled material to avoid UK plastic tax and can, as an option, be manufactured from 100% recycled material. Dolly Max also improves transport efficiency, increasing vehicle fill by 20% compared to standard roll cages. In addition, Loadhog offers a swap-out scheme at the end of the packaging’s life, when it can be reground and remoulded into a new, reusable solution.
CMC Packaging Automation, a global supplier of fully automated right-sized packaging solutions, has announced a strategic partnership with Correns corporation, a distributor of advanced machinery and industrial solutions in Japan. This collaboration marks a significant milestone in CMC’s mission to support Japanese retailers and logistics providers in achieving greater efficiency, sustainability, and customer satisfaction through packaging automation.
Since 2015, when the first CMC CartonWrap was introduced to the Japanese market, CMC has delivered multiple innovative right-sized packaging solutions to leading clients across retail and third-party logistics. This track record has confirmed CMC’s leadership in Japan as the trusted provider of packaging solutions that optimize processes, reduce waste, and enhance sustainability.
Correns, headquartered in Tokyo, operates multiple offices across Japan and employs over 170 professionals, including a dedicated team of service engineers and technicians. With decades of experience in introducing and supporting advanced international machinery, Correns brings extensive market knowledge, technical expertise, and a robust service network to this partnership.
Together, CMC and Correns will: • Expand access to right-sized packaging automation for retailers and e-commerce companies. • Provide enhanced local sales and service support through Correns’ nationwide network of offices and technicians. • Accelerate the adoption of sustainable packaging practices, helping businesses meet both operational efficiency goals and environmental commitments.
“Japan is one of the most advanced and demanding logistics markets in the world,” said Francesco Ponti CEO at CMC Packaging Automation. “Our partnership with Correns represents a strong commitment to our clients in the region. Together, we will deliver packaging solutions that combine efficiency, innovation, and sustainability.”
Ivar Johansson, President of Correns Corporation added: “Correns is now proud to partner with CMC, a global innovator in packaging automation. By joining forces, we can provide our Japanese customers with the technology and support they need to remain competitive in a rapidly changing e-commerce and logistics landscape.”
This strategic alliance reflects CMC’s long-term vision to grow in Japan and to continue leading the market in fully automated, right-sized packaging solutions that benefit both businesses and the environment.
CMC Packaging Automation, a global supplier of fully automated right-sized packaging solutions, has announced the publication of its FY2024 Sustainability Report, marking a significant step forward in the company’s journey toward responsible growth and long-term value creation.
The report highlights CMC’s integrated approach to sustainability, where competitiveness, innovation, and market leadership are inseparable from climate action and social responsibility.
Key 2024 Achievements
• 11% reduction in total GHG emissions, including a 72% year-on-year reduction in Scope 2 emissions, aligning with the company’s newly approved targets from the Science Based Targets initiative (SBTi).
• Full activation of the CMC Tech Centre in Atlanta, a global hub for training, R&D, and co-engineering, reinforcing CMC’s role as the partner of choice for clients seeking both innovation and sustainability.
• Client-enabled environmental impact, including the avoidance of 36 million cubic meters of plastic filler, prevention of 936 K tons of CO₂eq emissions, and conservation of 451 K tons of cardboard through the adoption of CMC’s solutions.
Looking Ahead
As CMC moves into FY2025, its priorities are clear: scaling innovation, embedding ESG into governance, and strengthening cross-functional integration to deliver market-relevant, resilient, and environmentally responsible solutions.
“Our mission is to transform the packaging industry from within,” said Francesco Ponti, CEO and Chairman of CMC Packaging Automation “In 2024, we not only delivered innovative solutions but also measurable environmental and social impact across our value chain. With SBTi-approved targets guiding our decarbonization journey, we are scaling innovation and embedding sustainability into every part of our business. Together with our clients, employees, and partners, we are setting a new standard for responsible automation.”
Microline, an Italian company specialising in the design and manufacture of automatic end-of-line systems for the Tissue, Food and Cosmetics industries, presents its new AL 80 Maxi. This evolution of the successful AL 80 horizontal packaging machine was conceived to meet the new demands of the tissue industry and expand the product handling range. Greater flexibility, enhanced performance: the AL 80 Maxi widens the range of products that can be packed and optimises the packaging process, while retaining all the reliability and efficiency that Microline systems are known for.
Based on the well-established, compact structure of the AL 80, the new Maxi version features appreciable improvements in terms of both capacity and versatility. The machine is now able to handle single or double rolls up to 280 mm in diameter, and ensure high operational performance across an increasingly variable product range. Productivity remains a strength, as the AL 80 Maxi is able to pack up to 65 rolls per minute, depending on the diameter and collation settings. This improvement has not, however, been to the detriment of process precision or final packaging quality, thus ensuring constant, reliable production.
Developed with adaptability in mind
One of the main advantages of the AL 80 Maxi is the operational flexibility made possible by a mechanical and software architecture that has been optimised to switch easily between different collations and materials. The machine is designed for use with a vast range of wrapping films, from classic LDPE and POF to the more recent monomaterials and environmentally-sustainable materials. This makes it suitable not only for conventional manufacturing settings, but also for sustainability- and resource-saving-oriented lines. The machine’s compact design also makes it ideal for use in locations where production space is limited, without requiring structural alterations to the system.
Measurable efficiency
The AL 80 Maxi was designed to maximise its energy yield and minimise waste. From roll placement to the affixing of glueless labels and film sealing, each step of the packaging process has been optimised to ensure a rational use of energy and materials. The process takes place without generating waste or scraps of any kind, with snug-fitting, taut and well sealed bags, thereby reducing shrink tunnel energy consumption.
The machine is also designed for use with remote monitoring and diagnostics systems, allowing technicians real-time access to operational data, performance reports and maintenance alerts. This helps to reduce downtimes and improve production continuity.
Simple process, professional results
The operation of AL 80 Maxi follows a principle that is as simple as it is effective. The rolls are fed into the machine by a conveyor system that positions them properly and arranges them in single or double lines. When they reach the packaging station, the products are wrapped according to the set collation and precisely sealed with longitudinal (contactless) and transverse seals. The result is a stable, compact, distribution-ready pack.
With its AL 80 Maxi, Microline is consolidating its position as a leading technological partner for the Tissue industry. The new machine was conceived to satisfy the demands of an ever-evolving market by offering flexible collation settings, energy efficiency and compatibility with the materials of tomorrow. The natural evolution of an already successful and now even more complete model.
Cross Point Business Park in Coventry, UK, is home to a new multi-user DC featuring a high degree of automation equipment. David Priestman took a look.
Teenage girls go mad for the beauty and make-up retailer Sephora – I have first-hand knowledge of that! With 34000 products the company requires a fast-moving third-party logistics omnichannel operation that manages both ecommerce plus deliveries to the seven UK stores every other day. 30% of UK consumer purchases are now made online.
DHL Supply Chain provides this nationwide service from Coventry over three mezzanine floors of storage, picking, packing and despatch. With an average of 7000 consumer orders a day the ecommerce operation is busy all afternoon and evening. From the inbound area all products are checked, scanned-in and put away. The warehouse control and inventory management process is data intensive. DHL manage that as well as constant analysis of the warehouse layout, looking at fast-moving items and juggling the varying demand for beauty products, subject to swings in trends and loyalties. This enables products to be stored in high or low priority areas.
Pick of the Bots
The picking operation makes good use of ‘Chuck’ ‘follow me’ robots (pictured, top). 45 of them are leased from Ocado (OIA). The Chucks are used for building the customers’ orders, using software developed by OIA. The software tells pickers what cardboard boxes should be used for each order. The bot then drives along the pre-determined route and knows where to go, leaving the (human) picker to simply take each item, scan and place in the right box. Each Chuck is named after a famous singer, with my favourite being ‘Bowie’, which was taking a well-earned rest when I visited.
DHL has cleverly built its own automated packaging machines here that close, glue and label each completed box lid, handling 60% of the ecommerce packages here that are taken by conveyor to outbound. Before the consumer changes her mind, no doubt.
Hot SKUs
DHL Supply Chain (just one part of the global behemoth) has 180,000 employees, 1600 DCs in 50 countries and a 3PL market share of 6%. In the UK it operates 5000 lorries and vans, 450 DCs with 36,000 staff. “Global trade is still growing and is the life blood of our expansion,” UK & Ireland CEO Saul Resnick states. “Retail is in a state of flux. They need us to be fast and innovative. We offer them enterprise diversity without the logistics footprint.”
The company is committed to automating its warehouse processes as much as possible. Tim Tetzlaff is its head of Digitalization and Automation. “Innovation is only real when it is scaled,” he says. Warehouse space is at a premium, as is labour, and customer expectations continue to rise. Tetzlaff’s role is to oversee the selection of technology and then scale it – picking bots, goods-to-person systems, AMRs, AI and more. Ideas lead to research then proof-of-concept, productization, commercialization and finally the modular standardization of all automation for rolling out globally.
Reaching Out
Boston Dynamics new ‘Stretch’ bot (pictured, below) unloads pallets, lifting boxes on to conveyors. It constantly photographs packages and processes these to understand what is next and the trajectory of each manoeuvre. With a weight limit of 23kg it is being tested by DHL for use cases. With 10 currently deployed, the goal is to operate 1000 of them by 2030. Faster than a human at 600 cases per hour, it will replace ‘back-breaking’ work in (often) cold environments.
“We have a vision on where we allocate our labour; approximately 25% on putaway and replenish, 35% picking, 10% packing,” Tetzlaff explains. “It’s not about replacing people but changing their roles from strenuous, repetitive physical tasks, to managing robots. Managers and planners oversee both people and bots, using data for insights on-site. We want to be the best integrator of people, bots, IT and analytics for flexible stability, seamlessly integrating tech and data to continually and dynamically optimise operational service delivery.” Now that would be modern beauty.
Every good fulfilment strategy now requires automated, right-sized packaging for every product. David Priestman attended a customer innovation day in Umbria, Italy, to see how things should be done.
“There should be no excuses in designing packaging machinery – go beyond limits,” enthused Francesco Ponti (pictured below), the exuberant CEO of CMC Packaging Automation at the company’s annual CID event in delightful Citta di Castello, near Perugia. His company are advocates of utilising fully-automated packaging technology and claim to be the number one in packaging ecommerce machine supplies globally.
CMC is a family company, having been founded by Francesco’s father Giuseppe in 1980. Like the world’s biggest online retailer (who do not need the publicity of being named here!) CMC grew from garage to global in a generation. “We’re in a very good position,” says the open and good-natured Ponti. “We learn from our customers what the market needs and try to make them happy. We are one of the best in R&D and the time-to-market of new product launches. Fit the box around the product and don’t ship air!”
No Fillings
The company has offices in the UK, Germany and Netherlands, as well as 3 further sites in Italy and facilities in the USA in Georgia, North Carolina and Ohio. The Cleveland factory makes cardboard, which helps CMC to control the price of consumable materials supplied to customers and give confidence in the total cost of ownership estimates.
The North American market is huge for CMC, accounting for 58% of revenue, thanks in no small part, I understand, to that other company that started in a garage. It has 600 employees, 600 customers and partners, over 600 patents and more than 3000 systems have been installed so far. Turnover has trebled in the last seven years to €157m. Investment from KKR has enabled this growth, facilitating a succession of new machine launches, roughly one per year.
Optimize Outbound
The newest machines in the range include ‘Genesys’ (with Combo and Compact variants) for dynamic packing of multiple items regardless of shape and size into tote boxes without pre-consolidation; ‘Cartonwrap’ (plus XL and duo versions) for ecommerce 3D packing into unique, optimised cardboard boxes without void fillers; ‘Paper-Pro’ for bagging into perfect-size paper bags; ’Nexus’ for 3PL or retail use alongside AMRs and carousel technology.
‘Box first’ or ‘box last’ is often the choice in packaging and ecommerce operations. ‘Box first’ is for on-demand packing, created for each specific order, used in conjunction with an ASRS or pick-to-light system. ‘Box last’ is a ‘zero touch’ fully-automated operation fed by conveyors from inbound. DHL Brazil’s Luiz Proenca is managing warehouse operations for customers including Adidas. Migrating from plastic to paper packaging is part of a switch to a ‘circular economy’ approach. Speaking at CID he said, “the challenge for us is in handling wide variations in ecommerce packaging sizes in the same distribution centre, combined with the need for speed and under 24-hour deliveries. Customer experience is important.”
CMC’s Paper-Pro machine has replaced twenty-four manual packing stations in his warehouse. It meets the sustainability targets due to the 100% recyclability of packaging materials. “The machine is fast, with no downtime,” Proenca says. “It’s also easy to operate with a low learning curve. ‘Plug and play’ installation enabled us to connect it to our conveyors in a compact layout. We’ve standardised our parcels, can guarantee the quality of input packaging materials, creating package consistency and reducing void space. Scope, plan, implement, maintain was our mantra.”
Buffer Your Tote
Materials handling system providers like Element Logic are integrating CMC GeneSys machines with ASRS like the AutoStore, plus adding the middleware and software. Ane Furu, VP of Product Management discussed a project for the German lab equipment firm Avantor, in which small parts are stored in the ASRS, then delivered to the pick station. Vary-Totes are used to pack items which are fed into the GeneSys by conveyor.
“It’s a pick and pack process with zero-touch,” she says. “We have halved manually packed box numbers, saving 30,000kg of carbon weight per annum.” The GeneSys is 70% faster than manual operations. “It’s not a question of whether to automate,” Furu adds, “but how. Framing the problem is often more important than solving it. Orchestration is the key.”
Leveraging right-sized packaging is the challenge and Francesco Ponti unveiled new product launches at CID. “Covid caused a boom in ecommerce automation, with big investment,” he told me. “But growth has slowed, there is less greenfield development at the moment, but more brownfield projects to automate DCs. Growth in the sector is 8%, which is still super good!
Entry-Level Solutions
“The problem with brownfield DCs is they’re normally at 80% capacity and can’t stop operations during a transition to new systems. So we adapt to find new solutions for integrators: compact, plug & play and standalone.” Ponti estimates there are 1300 new fulfilment centres built globally per year. These suit advanced packaging automation systems. There are an estimated 15000 brownfield warehouse sites. CMC estimates that 5% of them will be automated in the next 5 years.
CMC has therefore launched new short and compact machines, including the ‘CartonWrap Duo’ (43 sq.m), ‘GeneSys Compact’ (36 sq.m) and ‘GeneSys Prima’ (under 30 sq.m). These create boxes on demand based on customer data and use cardboard flaps to close the lid without a separate lid-fitting process. There is no trimming of waste cardboard needed as it is used as a filler. The flaps act like a spring to close and make the box strong to protect items.
The ‘Super Vertical’ (pictured above) drew special attention. Just 3m x 3m x 3m it is a bagging machine that uses flexible or semi-rigid, padded bags. It will be able to use rigid boxes too shortly. The bag or box size is determined by scanning the item. The machine can fill 500 bags per hour, single or multi-item, label, print and apply to the envelope. This clever product needs just one day to install, can be placed up against a wall or on a mezzanine and is ideal for 3PLs. Two manual packing stations represent the same space as one Super Vertical machine.
“Carton paper, corrugated paper, bubble or pressure-resistant paper are all cheaper than boxes,” Ponti concludes, “so envelopes are the future because couriers are overtaking postal operators and winning the postal market.” Limitless customer opportunities lay ahead.
Mosca GmbH, a manufacturer of straps, and twelve other European companies in the ‘Project Alliance Strapping’ (PAS) are warning of potential risks when reusing strapping. Reuse can lead to significant material weakness, particularly at welded joints, which directly affects transport safety on european roads. This has been confirmed by recent independent studies. In light of the new EU Packaging and Packaging Waste Regulation (PPWR), the alliance is calling for an exemption for strapping materials to promote sustainable recycling strategies without jeopardizing transport safety.
The EU Commission is currently discussing a potential exemption for strapping materials via a delegated act under the PPWR, which took effect in February. The PPWR aims to reduce packaging waste and promote circular economy through recycling. It also includes mandatory reuse quotas for strapping materials. In response, Mosca and the straps project alliance submitted a comprehensive, independent position paper to the EU Commission containing detailed study results. “We support the goals of the PPWR, but the safety of transported goods and the stability of supply chains must be ensured. This is not the case with multiple use,” explains Dr. Martin Bussman, Vice Chairman of the board of straps project alliance and Director Material Innovation at Mosca. “The position paper provides a reliable, factual basis that the EU Commission should definitely consider into the exemption.”
The PAS is an association of 13 leading European companies in strapping industry, including Mosca, Teufelberger, Fromm, Sekisui, Messersi and others.
Technical studies prove safety risks during reuse and multiple use
Independent technical tests, carried out by the Fraunhofer Institute for Microstructure of Materials and Systems IMWS at the Mosca Tech Center in Waldbrunn, provide the scientific basis for this requirement. The focus was on mechanical and thermo-mechanical testing according to international standards. This included the horizontal force test according to the EUMOS 40509 standard, the ISTA 1E inclination and vibration test, and tensile tests on various belt areas, particularly on the critical weld seams.
The results are alarming: After just one use, the welds on polypropylene (PP) and polyethylene terephthalate (PET) strapping are at 47 to 60 percent of their breaking strength on average. With repeated use, the tensile strength of PP straps decreases by up to 34 percent. Additional thermal stresses caused by temperature fluctuations between 40°C and -30°C further weaken them. This further compromises the integrity of the material during its practical application. It is particularly problematic that such stresses cannot be documented under real transport and storage conditions.
“These data make it clear that reuse poses considerable safety risks to goods and people”, explains Bussmann. The project alliance therefore favours a pragmatic regulatory solution. Rather than relying on potentially dangerous reuse, the use of high-quality post-consumer recyclates should be strengthened, and strapping material should be exempted from general reuse quotas of PPWR regulation. This is the only way to ensure permanently safe, resource-conserving transport packaging. “Additionally, the more frequently transport packaging is reused, the more often it needs to be inspected and maintained. This is not technically feasible or economically advantageous.”
Reusable solutions often less sustainable than expected
From an ecological standpoint, blanket reuse is not a viable solution either. A second study shows clearly the limitations of current reusable strap systems. The study analyzed standard market alternatives, such as mesh boxes with straps, tension straps with tarpaulin, and straps with tension clips. All alternatives were compared in the categories of safety, reusability, environmental impact and cost-effectiveness.
Technically, the alternative variants revealed significant weaknesses. Strapping material with clips, as the closest alternative to disposable straps, lost significant tensile strength and elasticity after just two cycles in reuse. These are key properties for load securing and transport safety. Tension straps with tarpaulin achieve 50 to 150 cycles depending on use, but they are highly susceptible to UV radiation and wear out quickly if you use them incorrectly. Mesh boxes with tension straps can withstand 200 to 300 cycles.
However, they are heavy and bulky in handling. Both aspects make them unsuitable for recurring applications. On top they would require extensive maintenance and documentation of each reuse cycle. Additionally, the return transportation of reusable components must often be shipped over long distances within Europe, resulting in considerable logistical costs or local storage. This includes additional transportation distances and result in increased greenhouse gas emissions, such as CO₂ emissions. In addition to that higher storage and personnel costs occur and the need to provide replacements in the case of loss or defects. In heterogeneous supply chains with changing customers, setting up a functioning reusable system is nearly impossible to realize this concept. “The results clearly show that the effort involved is in no proportion to the gained benefits,” explains Bussmann.
Disposable strap is often more advantageous in terms of sustainability
A life cycle analysis also shows that disposable straps have a better carbon footprint than reusable alternatives in many cases, even though they are used only once. Its low material usage, light weight, and high recyclability make straps an environmentally friendly packaging material, especially when made from post-consumer recyclate.
“It’s crucial to consider these facts when we talk about ecological responsibility,” Bussmann continued. “Token politics won’t help. We need solutions that are practicable, safe, and demonstrably sustainable.”
The PAS’s will be continue it’s work towards a sustainable circular economy. Next step to take will be the increased use of post-consumer recyclates in straps. The alliance is working to close material cycles and significantly reduce resource consumption, such as energy and plastics. “The PAS stands for practical solutions that combine safety and sustainability,” says Bussmann. “We will continue to contribute with our expertise in the future – in dialogue with politics, industry and society. Only an evidence-based approach will enable us to design the truly sustainable packaging solutions of the future.”
Inotec is proud to introduce its latest innovation in smart labelling – RFID Inmould Labels – a durable, high-performance solution that offers permanent identification and real-time tracking for reusable containers, even in the most demanding environments.
Bringing together the advantages of RFID Auto ID and in-mould labelling, Inotec’s RFID Inmould Labels offer durability, accuracy and sustainability. Developed in-house and tested in live customer applications, they are already helping leading logistics and packaging companies move away from single-use plastics while gaining full transparency across their supply chains.
Smart tray tracking at scale
A recent collaboration with EPT (Euro Plant Tray) demonstrates the real-world benefits of this solution. In the plant wholesale sector, over 95% of trays are currently single-use, contributing to around 40,000 tonnes of discarded plastic waste each year in Europe alone. EPT sought a reusable alternative that could deliver both environmental gains and digital traceability.
Working with EPT, Inotec developed a customised RFID inmould label that is seamlessly bonded to the reusable tray during injection moulding. This label offers exceptional durability – it is flush with the surface, waterproof, UV-resistant, and resistant to cleaning chemicals and mechanical impacts. Despite its compact size, it delivers a high-performance read range and allows bulk scanning of up to 1,000 trays simultaneously, with no line-of-sight required.
EPT’s trays now feature a secure, embedded RFID label that supports real-time tracking, inventory management, and cross-border reuse. The RFID inmould label is helping EPT reduce waste, optimise its processes, and set a new European standard for smart, reusable transport packaging.
Advanced performance, built to last Inotec’s RFID inmould labels are based on its own INO-TAG DIOBOND range and incorporate high-performance NXP RAIN RFID chips.
Key benefits include:
● High-speed scanning – multiple tags can be read simultaneously, even at distances of up to 15 metres
● No line-of-sight required – increasing speed and accuracy while reducing labour
● Secure, high-capacity data storage – with the ability to store encrypted tracking and logistics data
● Extremely durable – scratch-proof, smear-proof, waterproof and resistant to chemicals and temperature fluctuations
● Fully recyclable – made from the same material as the container for easier recycling
● Reduced energy use – thanks to in-mould’s one-step automated production process
Ideal for regulated and high-compliance sectors RFID inmould labels are particularly suited to industries where hygiene, traceability and security are critical. In food and pharmaceuticals, the edgeless bond eliminates contamination risk and withstands freezing, washing and sterilisation. IML is also compliant with strict FDA regulations and prevents label tampering or counterfeiting, which is critical for protecting intellectual property and public health.
“With RFID Inmould Labels, we’re combining durability, traceability and environmental responsibility in one powerful solution,” says David Stocker, General Manager at Inotec. “As seen with EPT, this technology helps our customers meet growing regulatory demands, streamline their processes and take a major step towards a circular economy.”
