DHL says it has successfully implemented reusable pallet wrap within its operations and with customers, said to save around 300 grams of plastic per pallet. A finalist in this year’s Sustainability Awards in the Commercialized Driving the Circular Economy category, we spoke to the company to find out more.
You’re a finalist in the Sustainability Awards 2025. Congratulations! To start off, could you summarize your entry, in less than 50 words?
We have successfully implemented a reusable pallet wrap to use internally within our operations and with our customers. This solution saves about 300 grams of single use plastic per pallet and ensures better stability and handling of our palletized goods.
Why do you think the judges were impressed with your entry? Tell us about what is innovative about your project and/or about its impact on packaging sustainability.
The judges were likely impressed with our entry because we are pioneering a reusable pallet wrap solution at scale, making us the first logistics company to replace single-use plastic wraps. This innovative project saves about 300 grams of plastic per pallet and introduces design enhancements that improve adaptability and durability.
Transitioning to this solution involves modifying processes to ensure effective reuse. We carefully selected lanes and customers to establish a reliable return flow for the reusable pallet wrap. This required developing criteria for facilities and implementing ongoing training to shift the mindset that single-use is easier - a significant challenge given the long-standing reliance on cardboard boxes and single-use wraps.
Our new design, developed with our supplier based on initial feedback, allows the wrap to accommodate various pallet sizes and features improved durability with the introduction of Velcro straps. While the design is still evolving, we are confident it will continue to improve over time.
Lastly, in alignment with the Packaging and Packaging Waste Regulation (PPWR), we are actively developing a comprehensive reuse system to ensure full compliance by 2030. By addressing both functionality and environmental impact, we are setting a new standard in the industry for sustainable packaging practices.
Finally, can you tell us about the ongoing development of your project, e.g. how your innovation/initiative has been received by the industry, or what the next steps are in commercialization/product development?
The ongoing development of our reusable pallet wrap project has been met with positive reception internally. Within our organization, there is a strong commitment to reducing packaging waste, increasing space utilization in our fleet, and transitioning to as many reusable options as possible. This aligns perfectly with our sustainability goals and reflects our proactive approach to innovation.
Externally, we’ve seen significant interest from customers who are eager to join and test the solution. However, the challenge lies in changing established processes and mindsets, which can be a barrier to adoption.
Additionally, the uncertainty surrounding the Packaging and Packaging Waste Regulation (PPWR) targets has created hesitation among companies. Many are reluctant to make the shift to reusable solutions until there is legal clarity on whether pallet wraps will be included in the regulations.
Moving forward, our next steps include continued collaboration with our customers to pilot the solution, gather feedback, and refine the design. We are also committed to developing a robust system for reuse that aligns with the evolving regulatory landscape, ensuring that we are well-positioned to meet compliance requirements and lead the industry in sustainable packaging practices.
Next year’s Sustainability Awards will take place during the Sustainable Packaging Summit in Utrecht, Netherlands, 10-12th November 2026. You can find out more here.
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