Waste Reduction

At our Poly-clip cafeteria in Hattersheim, we place great importance on the responsible use of food. That’s why we offer a selection of frozen meals daily, which we prepare fresh and on demand. Our offer is complemented by a salad bar with fresh ingredients, a free daily changing soup, and freshly prepared sandwiches upon request.

With targeted purchasing and precise planning, we ensure that only the amount needed is provided. This allows us to offer a balanced selection while avoiding food waste.

Every sheet of paper saved protects the environment and reduces waste. That’s why we at Poly-clip are committed to minimizing paper consumption at our locations in Gedern and Hattersheim. A key lever for this is the digitalization of our processes. Wherever possible, we replace paper-based procedures with digital solutions. Controlled paper output ensures that only the necessary amount is printed. As part of this initiative, we have reduced the number of printers and continuously evaluate further savings opportunities.

To unlock additional potential, we have launched an internal idea competition. All employees are invited to submit suggestions on how to further reduce paper consumption—because together, we find the best solutions!

These efforts are already showing results, and every printout we avoid contributes to our sustainable approach—motivating us to continue on this path.

At Poly-clip System, we don’t see machining tools as disposable items but as valuable resources. That’s why, for years, we have relied on the FRAISA ReTool® process to refurbish used tools. By consistently separating carbide waste and implementing our custom regrinding standards, we saved 5,425.54 kg of CO₂ in 2023 alone.

The ReTool® process restores tools to their original performance, lowers costs, and optimizes our processes. The circular economy enabled by FRAISA consumes 70% less energy and reduces CO₂ emissions by 40% compared to producing new tools from recycled carbide.

These measures extend the lifespan of valuable resources and contribute actively to resource conservation—an achievement we take pride in.

At our Gedern plant, we implement smart solutions for optimal resource utilization. A prime example is the reuse of waste heat from our four compressed air compressors.

For several years now, a specially installed air heating system has been capturing waste heat and feeding it back into the production process. This allows us to cover a significant portion of the heating needs for belt loop production.

This system not only enables significant energy savings but also actively reduces CO₂ emissions. A testament to how technological innovation and sustainable action can go hand in hand.

Our new site in Hattersheim sets new standards for energy savings. Thanks to modern construction and energy-efficient technologies, we have reduced electricity consumption per cubic meter of space by 70%—and gas consumption by an impressive 74%.

These savings are a key step in minimizing our environmental footprint. We think long-term and responsibly—not just for our company but also for future generations.

The new site demonstrates how Poly-clip combines innovation and energy efficiency. With this commitment, we remain true to our mission of conserving resources and actively contributing to the energy transition.

A comfortable indoor climate and sustainable energy use do not have to be a contradiction. At our production facilities and offices at Promar in Poland, we rely on an innovative climate control system with heat recovery that significantly reduces energy consumption. Instead of relying solely on fresh outside air, we operate a closed-loop system: 70% of the air is recirculated, while only 30% is fresh air intake.

This technology significantly reduces energy consumption, as less heating energy is needed for our production halls and office spaces. In this way, we make an important contribution to resource conservation—while ensuring a pleasant working environment.

Water is one of our most valuable resources, and we are committed to using it responsibly. At Promar in Poland, we operate a mechanical-chemical wastewater treatment plant that ensures all water from our production process is carefully purified before being discharged into the municipal wastewater system. This actively helps protect the environment and reduces the burden on downstream treatment facilities.

Our goal is to make the water cycle as sustainable as possible. Through targeted treatment, we ensure that the water is returned in a condition that meets the highest environmental standards. This contributes significantly to water conservation while protecting valuable natural resources.

We continuously invest in modern technologies to make our processes even more efficient and environmentally friendly – a clear commitment to eco-conscious production for the benefit of nature and future generations.

We have adjusted our processes in Eppertshausen to conserve resources and reduce waste. The use of packaging film has been significantly reduced, existing materials are consistently reused, and used cardboard is not discarded but processed directly into cushioning material for shipping using a special cardboardshredder.

This allows us to avoid purchasing new filling materials and creates an internal cycle that makes meaningful use of existing materials.

Each measure demonstrates how conscious actions improve processes and make materials usable in the long term.

In the logistics departments at Poly-clip System’s Hattersheim site, cardboard boxes were previously labeled using numerous label rolls. In addition, shipping documents had to be printed and attached, a process that required considerable material and time.

With the use of a mobile, digital labeling system, texts, barcodes and variable data can now be printed directly onto cardboard boxes, pallets or films. Label rolls and additional printouts are therefore largely no longer required.

As a result, waste is significantly reduced, resources are conserved, and a more environmentally conscious approach to materials is encouraged in everyday operations.

Efficient processes and environmental protection are not mutually exclusive. At Poly-clip in Hattersheim, a cardboard and baling press ensures that cardboard is compacted directly on site. Long transport routes to external collection points are eliminated, and the previously necessary manual shredding is no longer required.

By processing recyclable materials immediately, the volume of waste is significantly reduced, the work area remains clean and safe, and warehouse logistics are more organized. The press operates in a space-saving and efficient manner – actively helping to conserve resources and reduce environmental impact.

At Podanfol in Poland, plastic production waste is processed efficiently to create new plastic pallets.

The process begins with the targeted collection of production waste suitable for recycling. This waste is processed into regranulate at a recycling facility and then formed into new plastic pallets using injection molding.

In this way, production waste is not discarded but reused as valuable raw materials for useful products. The entire process actively contributes to conserving resources and reducing environmental impact.

The consistent reduction of production waste is driven by targeted planning, technical optimization, and employee expertise at Podanfol.

A key approach is the careful grouping of orders by colors and film types. This optimizes material usage, reduces unused components, and makes the overall production process more efficient. Planned and cyclical machine maintenance minimizes machine downtime and prevents unnecessary material loss.

Employee training and awareness also play an important role: workshops and further education highlight the importance of correct machine operation, enabling more precise use of raw materials and significantly reducing waste.

The automation of quality control using modern image processing systems not only improves production quality but also reduces environmental impact by minimizing defective products and optimizing material usage.

Through these coordinated measures, production waste is sustainably avoided while valuable resources are preserved.

A digital stamp is now used for a wide range of documents at all German sites. The previously necessary stamping, signing, and scanning of paper documents is largely no longer required.

The idea of saving paper through the digital stamp and digital signatures was awarded second place in the Poly-clip Sustainability Competition – an achievement we are very proud of. At the same time, the process remains dynamic: feedback from users and recipients is continuously incorporated.

The goal is to reduce paper consumption to a minimum and thus conserve valuable resources.

In the kitchen and office areas, the existing lighting was gradually converted to LED technology. The goal is to use light in a targeted and needs-based way, avoiding unnecessary energy consumption.

The transition is taking place at Project Food in Hungary and provides consistent, comfortable lighting for the workplace. LED lights consume less electricity, have a long service life, and need to be replaced less frequently. This enables a more conscious use of both energy and materials.

The new lighting solution reflects a responsible approach to resources and demonstrates how thoughtful measures can reduce unnecessary consumption.