According to the European Chemicals Agency (ECHA), microplastics are defined as all synthetic polymer particles smaller than 5 millimetres. This means that the raw materials used in our rigid plastic packaging production, both virgin and post-consumer recycled, are technically microplastics. While the production process itself is a closed system, posing no risk of spillage, several steps in the supply chain (e.g. inbound transportation, storage) represent potential points where plastic could spill into the environment.
ALPLA first launched the Zero Pellet Loss (ZPL) initiative in 2015, recognising that any loss of raw materials has both environmentally and economically adverse impacts. The program was revised structurally and its scope widened globally in 2024 through close collaboration between Corporate Supply Chain & Plant Engineering and Corporate Sustainability teams. The initiative aims to reduce and eventually eliminate the quantity of plastic pellets lost during manufacturing processes, prevent resin pellets from polluting water sources, maintain a safe working environment for employees and promote cleanliness at production sites.
ALPLA’s policy is to prevent material loss through optimised production processes and to minimise pellet loss through the reinvigorated Zero Pellet Loss programme. While the initiative focuses on ALPLA’s production sites, we also engage our key raw material suppliers. This topic is one of the key sustainability expectations placed on them, ensuring they take responsibility for a clean unloading environment when delivering pellets to any ALPLA location, for avoiding resin spillage and for cleaning up any spilled resin.
ALPLA’s voluntary target is to achieve zero pellet loss at production sites globally by the end of 2025, which translates to zero plastic particle (visible without tools such as microscopes) litter or potential leakage into the environment (e.g. into water or soil). This involves implementing stringent procedures and best practices in pellet handling processes such as storage, transportation and packaging. The following actions contribute to the success of the programme:
Clear responsibilities: at all ALPLA plants worldwide, responsible colleagues have been assigned to audit the plant and identify countermeasures which are then implemented by interdisciplinary local teams.
Training and awareness: ALPLA conducts ZPL training sessions and provides best-practice examples to employees and suppliers.
Assessment and monitoring: the ZPL initiative includes a self-assessment tool and questionnaire to monitor the status of ZPL implementation at various plants. This helps identify areas for improvement and ensure continuous compliance.
Annual audits and countermeasures: plant responsibility holders are mandated to conduct at least one internal audit per year and look for any non-conformity (i.e. instances of pellets potentially leaking into the environment). As a follow-up, countermeasures (preventive measures such as installation of filters, mesh drains, suction devices and small walls as well as regular cleanup of any spillage) are implemented before confirming the given plant’s ‘Zero Pellet Loss’ status.
Supplier engagement: ALPLA expects its raw material suppliers to adhere to the ZPL principles and raise awareness among their employees and chosen carriers through regular training sessions.
