Recycling Week 2025 is here!
PPL Plastic Solutions Leads the Way in Sustainable Packaging for Recycling Week
As the world continues to pivot toward sustainable practices, PPL Plastic Solutions is taking meaningful strides to reduce industrial waste and lead by example.
This Recycling Week, we shine a spotlight on their innovative "Design for Recycling" project, which has significantly reduced landfill waste through the development of reusable plastic coils and reusable pallet wrap.
From Waste to Reuse: Closing the Loop
PPL Plastic Solutions, a specialist in plastic profile extrusion and injection moulded parts, once relied heavily on single-use cardboard coils and plastic cling film to transport products safely. Weekly, this meant approximately 1,000 cardboard coils and 4,200 meters of plastic wrap were used — both ending up in landfill after one use.
In late 2019, with sustainability becoming a key priority for their parent company, PPL took the lead in developing long-term solutions that would transform their packaging methods and environmental footprint.
Innovation #1: Reusable Plastic Coils
By mid-2020, the team embarked on the development of a durable, reusable, and recyclable plastic coil, leveraging their in-house manufacturing capabilities. After multiple trials to ensure strength and reliability, the new coils were successfully rolled out in October 2020.
The results?
- 16.2 tonnes of waste diverted from landfill
- 98.75% return and reuse rate
- Damaged coils are recycled and re-moulded into new ones, creating a closed recycling loop
This robust system also includes an incentivised returns scheme to ensure high return rates and promote circular use.
Innovation #2: Reusable Pallet Wrap
Recognising the inefficiency of single-use plastic film, PPL introduced a reusable pallet wrap made from durable polyester mesh, industrial-grade Velcro, and elastic. This system, launched alongside the coils in October 2020, eliminates the need for disposable wrapping materials while maintaining product security during transport.
After one year:
- 1.5 tonnes of landfill waste prevented
- 100% return and reuse rate, with approx. 100 wraps returned weekly
Driving Impact Beyond the Factory Floor
Since implementing these initiatives, PPL Plastic Solutions has successfully diverted over 110 tonnes of waste from landfill — a testament to their commitment to sustainability and innovation. These closed-loop solutions not only reduce environmental impact but also enhance product handling, reduce costs, and improve customer satisfaction.
As Recycling Week reminds us of the importance of reducing waste, PPL Plastic Solutions stands as a shining example of how industrial practices can evolve to support a more sustainable future.
