In this project example, everything revolves around zinc wire and its transportation to European customers, which should be as safe and efficient as possible.

This is where Delta came in with a holistic process optimization, the first step of which involved a detailed analysis of the current situation at the manufacturer’s plant. Both the packaging and the processes surrounding the packaging were examined in detail in order to subsequently identify potential.

The existing process was as follows:
1. Preparing the packaging (returnable steel drum)
2. Filling the packaging
3. shipping throughout Europe by truck
4. Return of the empty containers

When looking at this workflow, the return transport of the empties is particularly noticeable, which caused immense costs as the drums could not be returned in a volume-reducible manner.

This is where Delta came in with an optimized packaging made of corrugated cardboard, which can also be filled directly on the line and prepared for dispatch.
The biggest advantage of this solution is the elimination of empties logistics in conjunction with simple and sustainable disposal of the disposable packaging at the end customer.

Thanks to the new packaging design made from a recyclable mono-material, the manufacturer can achieve the following effects in future:

1. Cost reduction in procurement
2. Reduction of storage costs (no storage of empties containers)
3. Elimination of the collection of empties

Together with the manufacturer, we have managed to establish a sustainable packaging process and logistics process and thus significantly improve the carbon footprint. Considering only the return transport of the empties, this means an annual saving of over 100 trucks, each with approx. 113 grams of greenhouse gas per tonne-kilometer.