Find out in the interview how a dedicated team at FORVIA HELLA plans to save 700 kilograms of plastic per year at HD Erwitte with an innovative, plastic-free shipping bag.

In a world increasingly affected by the negative impacts of plastic pollution, reducing plastic consumption is becoming more and more important. A significant step in this direction is the UN Global Plastics Treaty, which aims to create an international agreement to combat plastic pollution.

At FORVIA HELLA, a team is committed to introducing shipping bags that are completely free of plastic – out of frustration with unnecessary plastic waste.

In this interview, the team members talk about how this innovative idea came about and how it is being implemented.

You submitted the "Plastic-free shipping bag" project in response to the Earth Day call for projects. How did the idea for this project come about?

Albert Packhaiser: We have been concerned about sustainable packaging for quite some time. Jessika Duffy was really the pioneer in this area. She asked herself, "Is it possible that we have been using the same shipping bags for 25 years and nothing has improved?" So she simply asked suppliers if there were any alternatives. And lo and behold – there were!

Jessika Duffy: Exactly! I've been with HELLA for 25 years and nothing has changed in terms of packaging. The waste of plastic annoyed me more and more. At some point, I started looking for plastic-free alternatives. That's when I came across a supplier we already work with. They sent us samples of shipping bags made of corrugated cardboard instead of bubble wrap. We tested them as a team and thought they were great – especially because they don't contain any plastic. And they're just as easy to handle as before.

Hans Tissen: This is also an advantage for the carrier because the bags are smaller and take up less space.

How many of these shipping bags are used at FORVIA HELLA each year?

Hans Tissen: Approximately 696,000 per year. That's about 600 to 700 kilograms of plastic film alone that we have shipped so far. And because the old bags are made of composite material – i.e., paper and plastic firmly bonded together – disposal is also particularly expensive.

Are there any challenges associated with the changeover?

Jessika Duffy: Not really. Processing is just as easy as before. We can even send larger items that used to be packed in cardboard boxes with bubble wrap. Now everything goes into the new bag. It took about nine months from the first contact with the supplier to now. It took a while to finally find a manufacturer who could make the bags sturdy enough using corrugated cardboard.

And what about the carbon footprint of the new shipping bags?

Albert Packhaiser: We did a rough calculation: 600 kilograms of plastic film generate around 1,500 kilograms of CO₂. Recycled cardboard only generates 240 kilograms, while virgin fiber cardboard generates 720 kilograms. If we say that CO₂ emissions are halved, that should be about right. Of course, CO₂ is also emitted when paper is produced, but the difference is enormous.

What was the motivation behind the project? Was it just about the environment?

Hans Tissen: Environmental aspects were clearly at the forefront. But costs also play a role, of course. When I started as a packaging planner, I saw many opportunities for optimization - in terms of space utilization, volume, and materials. Switching to the new bag was one of the simpler measures with a big impact.

What's next? Is there already a timeline for the final implementation?

Jessika Duffy: The next step is to get the bags in the desired sizes and test them in everyday use. We are currently conducting a field trial to see what the feedback is like. If there is no negative feedback, we will roll out the bags across the board.

Hans Tissen: I expect that we will have sufficient initial feedback from the market after a few months.

Are there any further plans to reduce plastic consumption at FORVIA HELLA in HD Erwitte?

Hans Tissen: Absolutely! Our interior packaging for headlamps is currently made of 100% plastic and foam. For over a year and a half, we have been working on an alternative solution that is made from 95% cardboard and more cost-effective in all aspects, i.e., in terms of material, handling, and along the entire logistics chain, from delivery to shipment. This would also enable us to save around 3 tons of plastic waste per year, with an upward trend if we expand this concept and implement it in other plants. Our long-term goal is to work completely plastic-free. It's a process, but we're on the right track.

Thank you very much for the interview and your commitment to greater sustainability!