A new step towards a circular economy in the packaging and logistics sector. Dutch brewery Royal Grolsch and Schoeller Allibert, a leading company in reusable packaging systems, have launched an innovative sustainability project: pallets made entirely from post-consumer recycled plastics.
A Partnership for Sustainable Innovation
For over four centuries, Grolsch has combined tradition and innovation in beer production. Its mission to reduce environmental impact has led the company to collaborate with Schoeller Allibert for a more efficient and eco-friendly transport system. Sharing the goal of a functional circular economy, the two companies have developed a lightweight and durable pallet that enhances logistical performance while reducing CO₂ emissions.
Old Pallets, New Challenges
The previous pallets used for transporting kegs had several drawbacks: excessive weight, which increased costs and emissions, as well as outdated moulds that compromised reliability. Grolsch saw this challenge as an opportunity to optimise its supply chain with a more efficient and environmentally friendly solution.
“Replacing the old pallets allowed us to address the issue from a sustainability perspective," explained Joost Nawijn, Packaging Material Development Specialist at Koninklijke Grolsch. "We wanted a lighter alternative made from recycled material without compromising quality and functionality”.
The Innovation of Recycled Plastic
Schoeller Allibert designed a pallet tailored to Grolsch’s needs, reducing its weight by 12 kg compared to previous models. The secret? A honeycomb structure that ensures strength and lightness, combined with a high-pressure injection moulding process that guarantees greater durability. The material used comes from post-consumer bottles and packaging, as well as old recycled pallets, cutting emissions by 83% compared to traditional virgin plastic pallets. But sustainability doesn’t stop there: once they reach the end of their lifecycle, the pallets are collected by Schoeller Allibert and recycled, closing the circular economy loop.
Efficiency and Reduced Environmental Impact
The new design offers significant advantages for the brewery’s daily operations. The reduced weight makes handling with forklifts easier, while the stackable configuration allows for a gradual transition between old and new pallets, optimising space and reducing the number of return trips. The result? Lower CO₂ emissions and more sustainable logistics.
The new pallets came into operation in January 2025, demonstrating how the collaboration between Grolsch and Schoeller Allibert can generate innovative solutions where operational efficiency, emission reduction, and cost savings go hand in hand.
