Reusable packaging in B2B logistics: how does the PPWR promote a closed-loop system?

Reusable packaging (PPWR) is one of the most important issues for manufacturing, logistics and distribution companies operating in the B2B sector. The EU’s PPWR Regulation is shifting transport logistics away from a „use-and-throw-away” model towards one in which pallets, crates, containers, trays, drums and canisters are to circulate within a reuse system. The European Commission states that, from 1 January 2030, economic operators in the EU must ensure that at least 40% of transport and sales packaging is reusable; this requirement applies, amongst other things, to pallets, collapsible plastic crates, boxes, trays, plastic crates, intermediate bulk containers, buckets, drums and canisters.

For B2B companies, this means they need to redesign the flow of packaging within the supply chain. Simply purchasing more durable crates is not enough. PPWR requires a system for: identifying packaging, returning it, cleaning it, repairing it, reusing it, recording its cycles and settling accounts between partners.

What is reusable packaging at PPWR?

Reusable packaging is not simply any packaging that can physically be used more than once. In practice, it must be designed, manufactured and integrated into a reuse system. This means that the company should have a practical mechanism in place for the return, inspection, preparation for reuse and reintroduction of the packaging into circulation.

Reusable PPWR packaging is not a product in its own right. It forms part of a logistics system that must allow for multiple cycles of use without compromising its protective and transport functions.

This is crucial for B2B. A pallet, crate or container may be durable, but if they remain with the recipient after delivery, get lost in the warehouse or end up as waste, they do not form a viable reuse system. A closed-loop system only begins when a company knows where the packaging is, who is responsible for it and when it will return to the next cycle.

Why does PPWR have such a significant impact on B2B logistics?

B2B logistics generates large volumes of transport packaging: pallets, crates, dividers, containers, buckets, drums, canisters, protective film and bulk packaging. In many sectors, this packaging is either used once or partially recovered without a formal system in place.

The European Commission states that the PPWR is intended to reduce the volume of packaging and packaging waste, cut down on the use of virgin materials, and support the transition to a circular economy. The regulation is intended to ensure that all packaging on the EU market is economically recyclable by 2030, whilst also increasing the use of recycled materials and reuse schemes.

B2B is particularly important for PPWR because it is easier to implement a controlled circulation system in business-to-business relationships than in consumer sales. The partners are known, deliveries are regular, routes are fixed, and packaging can be marked, counted and returned.

What are the reuse objectives for B2B transport?

The PPWR introduces targets for the reuse of transport packaging. The most important overall threshold is 40% of reusable transport and sales packaging from 1 January 2030. The European Commission also points out that the requirement covers formats such as pallets, collapsible plastic crates, boxes, trays, plastic crates, IBCs, buckets, drums and canisters.

By 2040, the target for transport packaging is set to rise to 70%, in accordance with the implementation guidelines relating to Article 29 of the PPWR.

Furthermore, the 100% target is of particular importance for specific closed-loop flows. The European Commission has clarified that the PPWR originally established the 100% reuse target for stretch film and pallet strapping used within companies and between companies within the same Member State, but these two formats were exempted from this specific 100% requirement by virtue of the delegated act of 25 February 2026.

Area	Objective / requirement	Significance for businesses
Transport packaging and selected retail packaging	at least 40% reusable from 2030 onwards.	the need to implement a return and record-keeping system
Transport packaging: a look ahead to 2040.	70% reusable target	the need for a long-term logistics strategy
Selected closed B2B flows	up to 100%, reusable in certain situations	particularly important in the context of ongoing relationships between plants and partners
Wrapping and pallet strapping	exempt from the 100% requirement, but covered by the general principle of reuse and minimisation	it is necessary to analyse the load-securing function and the alternatives

For B2B logistics, 2030 is not a distant date. It is the deadline by which the packaging return system should be up and running, rather than still at the design stage.

PPWR pallets and crates – which types of packaging are the most important?

In B2B logistics, transport packaging and load units are of the utmost importance. The PPWR covers a wide range of formats, but in practice, most of the work will involve those that are produced in large volumes or circulate between regular partners.

The most important formats are:

– wooden, plastic and specialised pallets,
– folding crates,
– plastic boxes,
– transport containers,
– logistics trays and baskets,
– IBCs, or intermediate bulk containers,
– buckets, drums, barrels and jerry cans,
– storage containers,
– returnable packaging for components,
– packaging designed to protect goods during transport between sites.

Not all formats will carry the same level of risk. Reuse is easiest to implement where the flow is repetitive: factory–warehouse, manufacturer–component supplier, distribution centre–shop, company–contractual customer.

What is a closed-loop B2B packaging system?

A closed-loop B2B packaging system is one in which transport packaging is returned to the sender, the operator or a shared pool after use, and is then prepared for the next cycle. The key point is that the packaging does not become waste after a single delivery.

In practice, a closed-loop system requires five components:

– the owner or operator of the packaging,
– the marking and identification of vessels,
– refund procedures,
– the cleaning, inspection and repair process,
– data on stock turnover, losses and damage.

The simplest example is a manufacturer that supplies components to a regular customer in plastic crates. The customer empties the crates, folds them up, places them in a designated area, and the carrier collects them with the next delivery. Each crate has an identifier, and the company knows how many cycles it has completed, how many have gone missing and how many require repair.

A reuse system is not just about reverse logistics

Reverse logistics is part of the system, but it does not cover the whole picture. PPWR requires a systems-based approach: packaging must be designed for reuse, integrated into a reuse system and maintained in a condition that allows it to fulfil its protective function.

The Commission’s technical guidance on the PPWR states that operators using reusable packaging must participate in an existing or new reuse scheme that complies with the requirements, and that reusable packaging should be prepared for reuse in accordance with specified rules.

The reuse scheme should include:

– rules on packaging ownership,
– standards for cleaning and repairs,
– maximum or target turnover time,
– liability for damage,
– a refund and settlement mechanism,
– instructions for the warehouse,
– data for reporting,
– the procedure for withdrawing packaging from circulation.

Reuse without a system is merely a statement of intent. Reuse with a system is a controlled business process that can be measured, documented and improved.

How can you prepare your supply chain for the PPWR?

Preparing the supply chain for reusable packaging should begin with a flow chart. The company needs to know where the packaging is produced, where it is filled, where it goes, who empties it and whether it can be returned.

1. Identify B2B flows

First, you need to identify recurring routes and business relationships. The best candidates for reuse are deliveries to regular customers, movements between your own sites, the transport of components, deliveries to retail chains and relationships with logistics operators.

2. Carry out an inventory of transport packaging

The list should include pallets, crates, containers, dividers, protective packaging, plastic film, tape, corner protectors and other transport components. For each item, the material, weight, volume, supplier, cost and reusability must be specified.

3. Assess which packages might be circulating

Not every type of packaging is suitable for reuse. It is necessary to check its durability, cleanability, resistance to damage, standardisation of dimensions, transport compatibility and traceability.

4. Determine the ownership model

Packaging may belong to the manufacturer, the consignee, the logistics operator or a shared pool. The lack of clear rules on ownership is one of the most common causes of losses.

5. Design a refund system

It is necessary to specify who collects the empty packaging, when, in what condition, in what quantities and at whose expense. Without this, a closed-loop system quickly turns into a storage facility for empty crates.

6. Keep a record

A company should measure the number of packages in circulation, turnover rates, losses, damage, return times and handling costs. Without data, it is impossible to determine the level of reuse or to optimise the system.

7. Test the system on a pilot basis

It is best to start with a single route, a single product group or a single customer. A pilot scheme allows you to check whether the packaging is being returned, where losses are occurring and whether the process is causing bottlenecks in the warehouse.

In practice, it is worth combining such a project with PPWR audit and a broader environmental audit, as reusable logistics has an impact on packaging, waste, data, environmental obligations and operational processes.

What data needs to be measured in a reuse system?

PPWR emphasises the importance of data. A company cannot simply state that it „uses reusable crates”. It should measure how many crates are actually in circulation, how many times they have been used, and what the level of wastage is.

The key indicators are:

– the number of packs in the pool,
– the number of packs dispensed,
– the number of packages returned,
– average turnover time,
– number of rotations per pack,
– the level of confusion,
– extent of damage,
– the cost of the repair,
– the cost of cleaning,
– the cost of return transport,
– the weight of single-use packaging replaced by reusable alternatives,
– emissions and logistics costs, if the company monitors them.

A reusable packaging data sheet is a useful tool. It should include details of the material, weight, owner, expected number of cycles, cleaning requirements, repair procedures, criteria for withdrawal from service and reporting procedures.

Pallets, crates and containers – what could possibly go wrong?

Implementing a reusable system can reduce costs and minimise waste, but only if it is well designed. Errors in the return logistics process can quickly eat into the expected benefits.

The most common problems are:

– failure by customers to return packaging,
– no room for empty crates,
– mixing packaging from different owners,
– lack of cleaning and quality control,
– damage after a few rotations,
– dimensions not suitable for shelving or transport,
– no procedure for lost packaging,
– a conflict over costs between the consignor, the carrier and the consignee,
– the pool’s turnover time is too long,
– no data available to document reuse.

The system should therefore be designed not only with a view to compliance with the PPWR, but also taking into account warehousing, transport, procurement, accounting and business partners.

Is reusable packaging always better?

Not always. Reusable packaging makes sense when it is reused a sufficient number of times, reduces waste and does not incur disproportionate logistics costs. If empty packaging has to be transported over very long distances without a return load, the environmental benefit may be reduced.

This is precisely why the European Commission has adopted a delegated act exempting stretch film and pallet strapping from the 100% requirement to be reused in certain situations. The Commission considered that the exclusive use of reusable stretch film and pallet strapping for transport within the same company, between affiliated companies or for deliveries within the same country could lead to disproportionate compliance costs.

The takeaway for businesses is straightforward: the PPWR promotes reuse, but a good system must be technically, economically and operationally viable.

Reusable packaging and the circular economy

Reusable packaging is one of the most practical examples of the circular economy. Instead of constantly buying new single-use packaging, the company manages a pool of resources that are returned to circulation.

In B2B logistics, GOZ stands for:

– lower consumption of raw materials,
– reducing packaging waste,
– better control over material costs,
– the possibility of standardising packaging,
– greater predictability of deliveries,
– easier analysis of the packaging’s life cycle,
– a stronger position in its dealings with B2B clients.

In this area, it is worth making use of GOZ package, because the introduction of reusable packaging requires not only a change in materials, but also a reorganisation of processes, data and responsibilities within the supply chain.

Reusable packaging and BDO, EPR and EU obligations

The PPWR does not replace national obligations. Companies must still analyse the BDO, EPR, LUCID and other schemes applicable to their sales markets. Reusable packaging may change the way reporting is carried out, but it does not automatically mean that obligations are waived.

The company should check:

– whether reusable packaging is being placed on the market,
– who owns it,
– who is responsible for keeping a record of it,
– when packaging becomes waste,
– is the packaging subject to the BDO,
– does overseas sales trigger EPR obligations,
– does the packaging require labelling,
– whether the data on mass and circulation are consistent with the documentation.

Companies operating internationally should combine a reuse system with compliance with packaging obligations in EU markets, and in the case of sales or deliveries to Germany, also from LUCID audit.

How should reuse principles be included in a B2B contract?

A closed-loop packaging system requires clear arrangements with partners. If the contract makes no mention of packaging returns, after a few months the company may not know where its stock of crates or pallets is.

It is worth specifying the following in the contract:

– who owns the packaging,
– who bears the cost of purchase, repair and cleaning,
– where the turn takes place,
– what is the maximum return period,
– how are damaged or lost packages accounted for,
– who is responsible for the records,
– is a security or deposit required,
– how is packaging collected with the next delivery,
– what are the standards for cleanliness and technical condition,
– how are disputes over shortfalls in the pool resolved?.

In a reusable system, packaging becomes a logistics asset. As it has value and circulates between companies, it must have an owner, return policies and associated data.

Example: a closed-loop system for crates between the manufacturer and the customer

A manufacturing company delivers components to a regular customer three times a week. Until now, it had been using single-use cardboard boxes and protective film. Following a PPWR analysis, the company is introducing reusable crates.

The new process is as follows:

The production department packs the components into labelled crates.
The warehouse scans the crates before dispatch.
The recipient empties the crates and places them in the return area.
The carrier collects the empty crates with the next delivery.
The company checks the condition of the crates, washes them and sends them on to the next cycle.
The system reports stock turnover, losses and damage.

After a few months, the company can see whether there are enough crates in the pool, how long each cycle takes, where delays are occurring, and which crates need repairing. This is the practical difference between „we have reusable crates” and „we have a reuse system”.

Who in the company should be responsible for implementation?

The introduction of reusable packaging requires cooperation between several departments.

Logistics is responsible for the flow and return of packaging. Procurement selects suppliers and negotiates terms. Production assesses the functionality of the packaging. The warehouse implements storage and control procedures. Quality Control checks for cleanliness, damage and product safety. Compliance analyses PPWR, BDO and EPR. Finance assesses the cost of the pool, depreciation, losses and deposits. Sales agrees terms with customers.

The greatest risk arises when a reuse project is assigned solely to the environmental protection department. Without logistics and operations, the system will not work.

If a company needs support in designing a process, it is worth combining comprehensive environmental consultancy from ongoing environmental support and an audit of current packaging flows.

Checklist for preparing B2B logistics for the PPWR

Do we know what sort of transport packaging we use in B2B?
Do we know the volumes of pallets, crates, containers, trays, drums and canisters?
Do we have any recurring routes where reuse can be implemented?
Is the packaging durable enough to withstand multiple cycles?
Do we have a system for labelling and identifying packaging?
Is it known who owns the packaging?
Do B2B contracts cover returns, damage and loss?
Does the warehouse have space for empty packaging?
Can packaging be cleaned, repaired and inspected?
Do we measure staff turnover, wastage and turnaround time?
Is the data linked to BDO, EPR and environmental documentation?
Do we have a plan for achieving our reuse targets for 2030 and 2040?

If several of the answers are „no”, the company should start by carrying out an audit of packaging flows and a PPWR risk assessment.

The most common mistakes made when introducing reusable packaging

The first mistake is buying durable packaging without a return scheme. A crate does not become reusable simply because it is sturdy.

The second problem is a lack of data. Without records, the company does not know how many packages are in circulation, how many have gone missing and how many times they have been used.

The third mistake is ignoring the recipient. The reuse system only works if the B2B partner has the facilities, procedures and motivation to return the packaging.

The fourth mistake is failing to take cleaning and repairs into account. Reusable packaging must retain its protective function and quality throughout successive cycles.

The fifth mistake is a lack of contracts. If the rules regarding ownership and liability have not been agreed, disputes over missing packaging are almost inevitable.

The sixth mistake is the assumption that reuse always reduces costs. Cost-effectiveness depends on the number of cycles, distance, wastage, cleaning costs and return transport costs.

FAQ - Frequently asked questions

Does PPWR require reusable packaging in B2B logistics?

Yes, the PPWR sets targets for the reuse of transport packaging and selected retail packaging. From 2030, at least 40% of such packaging is to be reusable, and by 2040 the target for transport packaging is set to rise to 70%.

Are pallets and crates covered by the PPWR?

Yes. The European Commission states that the reuse targets include, amongst other things, pallets, collapsible plastic crates, boxes, trays, plastic crates, IBCs, buckets, drums and canisters.

Do the film and straps used to secure pallets have to be reusable?

The European Commission has adopted a delegated act exempting pallet wrap and strapping from a specific 100% requirement regarding reuse in certain applications. However, these must still be considered in the context of the overall objectives of minimising packaging and securing the load.

What is a closed-loop B2B packaging system?

It is a system in which transport packaging is returned to the sender, the operator or a shared pool after delivery, and is then cleaned, inspected, repaired and reused. Record-keeping, return policies and the responsibilities of the partners are key.

Is reusable packaging always the best option?

Not always. Cost-effectiveness and environmental impact depend on the number of rotations, distance, return costs, wastage, cleaning and repairs. Implementation should be preceded by a flow analysis and a pilot scheme.

How do you start preparing for PPWR in B2B logistics?

It is best to start by carrying out an inventory of transport packaging, mapping B2B flows, identifying recurring routes, assessing return options and conducting a PPWR audit. Only then should you select specific pallets, crates, containers or an identification system.

Build an effective returns logistics system with Eko-Pro

PPWR reusable packaging will transform B2B logistics from a simple packaging cost into a packaging asset management system. Companies that map out their pallets, crates, containers and return flows in advance will be better prepared for the 2030 and 2040 targets.

If you want to check whether your supply chain is ready for reuse schemes, use PPWR audit, environmental audit or Eko-Pro’s comprehensive environmental consultancy services. You can also find out our full range of services for businesses or go to the tab Contact Eko-Pro and describe your current B2B packaging flows.