PPWR and pallet packaging: How to reduce packaging without compromising pallet stability

PPWR is changing the way manufacturers need to think about packaging.

The new EU Packaging and Packaging Waste Regulation puts greater focus on reducing packaging, using materials more efficiently and increasing reuse.

But for companies shipping products on pallets, one important question quickly arises:

How do you reduce packaging without compromising pallet stability?

Because less packaging only works if the pallet still performs throughout production, internal transport, storage and further distribution.

What is PPWR?

PPWR stands for the Packaging and Packaging Waste Regulation – Regulation (EU) 2025/40.

The regulation applies across the EU and introduces new requirements aimed at reducing packaging waste and improving how packaging is designed, used and reused.

Several important requirements will take effect towards 2030.

One of the key principles is that packaging should be designed so its weight and volume are reduced to the minimum necessary while still maintaining its functionality.

For manufacturers, that last part is crucial.

Less packaging must not lead to unstable pallets, damaged products or additional repacking later in the supply chain.

What does PPWR mean for pallet packaging?

Transport packaging is part of PPWR.

This includes packaging used to transport and stabilise goods, such as pallets, pallet wrapping and straps.

That means manufacturers increasingly need to take a closer look at the materials used on each pallet.

Can less material be used?

Can some materials be replaced with thinner alternatives?

And can the pallet itself be made more stable before additional packaging is applied around it?

Pallet stability starts inside the load

Stretch film and straps are often used to keep a pallet load together.

But if the individual product layers can move against each other, the outer packaging also has to control that movement.

Antim® anti-slip paper is placed between the product layers, where it increases friction and helps prevent products from sliding.

This creates a more stable load from the inside.

And that provides a better starting point if a manufacturer wants to reduce the amount of packaging used around the pallet.

Can anti-slip paper reduce stretch film consumption?

Yes, in the right applications.

By stabilising the product layers with Antim®, stretch film consumption can be reduced by up to 30%.

The actual result depends on factors such as product type, weight, pallet layer pattern, transport conditions and the existing wrapping setup.

Any reduction in stretch film should therefore always be tested and validated on the actual pallet load.

Antim® does not necessarily replace stretch film. Instead, it helps create stability between the product layers, so the stretch film does not have to compensate for an unstable load.

PPWR is not only about plastic

Much of the discussion around PPWR focuses on plastic.

But paper and corrugated board used in palletising should also be part of the calculation.

In suitable applications, traditional corrugated interlayer sheets can be replaced with much thinner Antim® anti-slip paper.

This can reduce paper consumption by up to 66%.

Antim® is also made from FSC®-certified paper and is 100% recyclable.

That means manufacturers can address several parts of their packaging consumption at the same time:

Up to 66% less paper and up to 30% less stretch film – while maintaining pallet stability.

The exact reduction potential will naturally depend on the individual pallet and production setup.

From corrugated sheets to Antim® – and more available warehouse space

Lower material consumption can also create benefits beyond the pallet itself.

Antim® takes up significantly less space than traditional corrugated sheets. This means manufacturers can free up valuable warehouse space when large volumes of corrugated board are replaced with thinner anti-slip paper.

In one Palcut example, storage requirements were reduced from 120 pallet spaces to 20 pallet spaces.

That frees up 100 pallet spaces for other materials and products.

What if anti-slip paper is supplied on rolls?

For manufacturers with high interlayer consumption, Antim® can also be supplied on rolls together with an automatic Palcut sheet dispenser.

The dispenser automatically cuts the paper to the required length directly from the roll.

This can provide several operational benefits:

• more sheets per pallet
• fewer paper deliveries
• more available warehouse space
• fewer refills at the palletising line
• potentially less production downtime

These are not PPWR requirements in themselves.

But they show how packaging optimisation can also support a more efficient production process

How can manufacturers prepare for PPWR?

A good place to start is to look at the complete pallet rather than each packaging material separately.

Ask questions such as:

Where do we use the most packaging today?

Which materials are actually necessary for pallet stability?

Can we reduce movement between product layers?

Can thicker materials be replaced with thinner alternatives?

Can we reduce packaging without compromising performance?

The goal should not simply be to use as little packaging as possible.

It should be to use the right amount of material while maintaining the stability and protection the pallet requires.

How can Palcut support manufacturers with PPWR?

Palcut cannot make a company’s complete packaging setup PPWR compliant.

But we can help manufacturers investigate one important part of the challenge:

Can you reduce packaging consumption while maintaining or improving pallet stability?

With Antim®, manufacturers can potentially:

• reduce paper consumption by up to 66%
• reduce stretch film consumption by up to 30%
• free up valuable warehouse space
• stabilise product layers from inside the load
• reduce refills when using paper on rolls

The exact result will always depend on the product and production environment.

But the starting point is simple:

Before adding more packaging around an unstable pallet, stabilise what is happening inside the load.

 

Want to see where you can reduce packaging without compromising pallet stability?

Talk to our team about your current pallet setup and the opportunities to optimise it.

Contact us

FAQ: PPWR and pallet packaging