In modern logistics, the idea that an ecological solution must necessarily be more expensive no longer holds true. The shift from a linear “use and dispose” model to circular logistics is becoming a competitive advantage – especially where packaging can be returned, repaired, and reused.
At Lemmacon®, practical experience confirms that reusable KTP boxes (foldable pallet containers) are a real game‑changer in this respect: they reduce the carbon footprint while at the same time optimising transport and storage costs.
What circular logistics (briefly) means
- The linear model works on the principle of “produce – use – dispose”, which is typical for single‑use cardboard packaging.
- Circular logistics aims to keep packaging in circulation for as long as possible: designing it for repeated use, enabling repairs, refurbishment, and, finally, recycling of the material.
- KTP boxes fit this concept very well thanks to their long service life, repairability (including the option to replace individual KTP box components with new ones) and 100% recyclability of the plastic at the end of the life cycle.
Durability that beats single‑use
Whereas single‑use packaging (cardboard, and in some cases even wood) often ends up discarded after a single trip, KTP boxes are designed for hundreds to thousands of logistics cycles in demanding operations. They are made from durable plastics (PP, HDPE) that can withstand impacts, moisture, and commonly used chemicals.
This robustness has a direct impact on sustainability:
- Waste minimisation: Thanks to their long service life, the need to manufacture new packaging is significantly reduced, which saves primary raw materials and energy, and secondarily the company’s finances.
- Recyclability: At the end of their life cycle, the material is 100% recyclable; internal Lemmacon® data show that tens of tonnes of recycled plastic are returned to circulation by Lemmacon® alone.
Logistics maths: less air, more goods
The biggest enemy of logistics efficiency is transporting air – especially when it comes to empty packaging within reverse logistics. The foldable design of KTP boxes provides an elegant solution to this problem:
- For return transport, the side walls are folded down into the pallet and covered with the lid (the so‑called “sandwich”), which significantly reduces the height of the box.
- In practice, this means a space saving of up to around 70% compared with non‑foldable or unfolded boxes of the same type, depending on the specific model and logistics scenario.
For our client Forvia, the use of foldable KTP boxes delivered a 79% saving in truck space compared with a scenario in which the boxes would be transported in the erected state. This is a concrete result from a real‑world project, not theoretical figures. Less volume taken up by empty packaging in trucks means fewer trips, lower fuel consumption, and lower CO₂ emissions.
Typical models: KTP 114 777 and 114 888
At Lemmacon®, the models most frequently supplied to customers are KTP 114 777 and KTP 114 888, which are among the most widely used foldable pallet boxes in European logistics.
Model
Both models are based on unified standards from manufacturer KTP, which makes them easy to integrate into existing logistics and compatible with commonly used handling equipment.
For each project, Lemmacon® defines the specific type, sleeve height, and internal dunnage so that the standardised box precisely matches the material flow and the load capacity required by the customer.
Simple model example of savings
Imagine a company that uses 1,000 KTP boxes, each completing 50 cycles a year:
- 50,000 cycles = 50,000 “replaced” single‑use packs, assuming that otherwise each shipment would be packed in cardboard or single‑use wooden packaging.
- By folding the boxes on the return trip, many more empty packs can be loaded onto a single truck; depending on the configuration, this can mean a reduction of dozens of trips per year, which directly lowers CO₂ emissions and transport costs.
The purpose of this example is to illustrate the principle: the more cycles a box can withstand, the greater the difference compared with single‑use packaging.
Circular economy in real projects
At Lemmacon®, theory is always validated in real‑world projects where circular principles (re‑use, refurbishment, recycling, rental) meet hard figures. Here are a few examples from practice:
Thermoplastik – combining new and used
For the Slovak plastic injection specialist Thermoplastik, it was necessary to design packaging for VW Tayron bumpers with an emphasis on part protection and cost efficiency.
- Solution: Instead of deploying completely new boxes, a combination of used and new components was chosen – refurbished plastic pallets and plastic lids from KTP boxes, complemented by a new sleeve.
- Result: Using existing components reduced the packaging price and significantly extended the life cycle of plastic parts that would otherwise have ended up as waste – circularity in practice.
Forvia – rental instead of purchase
For Forvia (a Tier‑1 automotive supplier), Lemmacon implemented a project for packaging seat frame structures in the form of a rental scheme.
- Solution: Instead of a direct sale, the client rented 1,450 pallet boxes equipped with cardboard sleeves made from recyclable material.
- Result: Pooling/rental is one of the highest forms of circular logistics – packaging does not lie idle in warehouses but is constantly used where it is needed; the client reduced CAPEX, and Lemmacon ensures that the packaging remains in good condition for further use.
Intelligent internal dunnage (inserts)
The KTP box itself is only the outer shell – true efficiency and sustainability often come from properly designed internal dunnage. The aim is to maximise the number of safely stored parts in a single pack (packing density), thereby reducing the number of boxes in circulation.
For parts for the Fiat Panda, the client used the Lemmaroll system (sliding textile pockets), which made it possible to safely place up to 66 visible parts in a single standard box without risk of scratching.
Higher packing density means fewer boxes, fewer handling operations, and more efficient transport – another step towards a lower carbon footprint per transported part.
When KTP boxes (for now) are not suitable
To remain objective, it is important to acknowledge situations where reusable KTP boxes are not the ideal solution.
- One‑off, short‑term campaigns without the possibility of reverse logistics (e.g. export to destinations from which the packaging does not return).
- Operations with extreme contamination or damage to packaging, where the boxes’ service life would be too short.
- Projects with a very low number of cycles where the initial investment in returnable packaging would not pay off economically; however, such requirements can often be addressed via packaging rental – which can be arranged even for just a month.
In other cases – especially in automotive and industrial logistics – KTP boxes have strong potential to become the standard.
Sustainability without compromise: what Lemmacon® can do for you
Implementing KTP boxes helps companies not only to meet internal ESG targets and respond to pressure to reduce CO₂, but also to increase the efficiency and transparency of the supply chain. The key is not to treat them as “just another box”, but as part of a comprehensive packaging and logistics concept.
Lemmacon® can support you for example with:
- Auditing current packaging flows and identifying where circular solutions make the most sense.
- Designing a complete packaging concept (KTP box + inserts) for specific parts and projects.
- Calculating total cost of ownership (TCO) and indicative savings, including impact on CO₂.
- Arranging purchase, rental (pooling), servicing, and refurbishment of packaging so that boxes stay in circulation for as long as possible.
Want to find out how many single‑use packs, how much CO₂ and how much money a switch to KTP boxes could save in your operation?
Arrange a short consultation or logistics mini‑audit with Lemmacon® – together, a circular solution will be found that makes sense both economically and ecologically.
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